Dodge - Ram 1500 2wd - Workshop Manual - 2006 - 2006

Factory Workshop Manual Make Dodge Model Ram 1500 2wd Engine and year Truck V8-5.7L VIN 2 (2006) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 10 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 11 Module - Sentry Key Remote Entry Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, refer to Keyless Entry Transmitter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 14 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS) and is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. The Sentry Key REmote Entry Module (SKREEM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC), the Powertrain Control Module (PCM)/Engine Control Module (ECM), the Gateway module (SRT10 vehicles with a hybrid bus only) and the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then listens for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends a valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 15 SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator status messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator status message from the SKREEM tells the EMIC to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator status messages to the EMIC to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM detects an invalid key or if a key transponder- related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The SKREEM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 16 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry Keyless Entry Module: Service and Repair Module-Remote Keyless Entry REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 19 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 20 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 21 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 22 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 26 Module - Hands Free Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 31 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 32 Module - Sentry Key Remote Entry Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, refer to Keyless Entry Transmitter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 35 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS) and is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. The Sentry Key REmote Entry Module (SKREEM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC), the Powertrain Control Module (PCM)/Engine Control Module (ECM), the Gateway module (SRT10 vehicles with a hybrid bus only) and the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then listens for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends a valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 36 SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator status messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator status message from the SKREEM tells the EMIC to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator status messages to the EMIC to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM detects an invalid key or if a key transponder- related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The SKREEM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 37 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry Keyless Entry Module: Service and Repair Module-Remote Keyless Entry REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 40 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 41 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 42 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 43 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/ module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 47 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close Sunroof / Moonroof Module: Customer Interest Body - Sunroof Glass Not Flush With Roof/Won't Close NUMBER: 23-040-06 GROUP: Vehicle Performance DATE: September 26, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software. MODELS: 2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF). SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 56 If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash SUNR" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 57 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash SUNR" screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close Sunroof / Moonroof Module: All Technical Service Bulletins Body - Sunroof Glass Not Flush With Roof/Won't Close NUMBER: 23-040-06 GROUP: Vehicle Performance DATE: September 26, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software. MODELS: 2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF). SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 63 If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash SUNR" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 64 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash SUNR" screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 65 Motor/Module - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 66 Sunroof / Moonroof Module: Service and Repair WARNING: THE EXCESSIVE FORCE LIMITATION (EFL) FEATURE MUST BE CALIBRATED ANY TIME A SUNROOF MOTOR/MODULE IS REPLACED WITH A NEW COMPONENT. FAILURE TO PERFORM THIS PROCEDURE COULD RESULT IN VEHICLE DAMAGE AND/OR PERSONAL INJURY. REMOVAL 1. Move glass panel to the fully closed position. 2. Disconnect and isolate the battery negative cable. 3. Remove headliner. 4. Disconnect the sunroof wire harness electrical connector. 5. Disconnect the four drain tubes (1) from sunroof housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 67 6. With the aid of a helper, support the sunroof and remove the eight fasteners (2) attaching sunroof assembly (1) to roof panel. 7. Remove the sunroof (1) from vehicle. INSTALLATION 1. Verify that glass panel is loose and slightly retracted. 2. Raise sunroof module assembly (1) and guide it carefully into position. 3. Hand start the eight screws (2). 4. Line up the locating holes and tighten the attaching screws (2) to 9 N.m (80 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 68 5. Connect the electrical connector (1). 6. Connect the drain tubes (1) to the sunroof. 7. Adjust the sunroof glass. 8. Connect battery negative cable. 9. Install the vehicle headliner. 10. Perform the sunroof position calibration. See: Body and Frame/Roof and Associated Components/Sunroof / Moonroof/Testing and Inspection/Programming and Relearning/Sunroof Position Calibration 11. Perform the Excessive Force Limitation (EFL) calibration. 12. Verify proper operation of the power sunroof system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement Technical Service Bulletin # F05 Date: 060701 Recall - ABS Control Module Replacement Revised July 2006 Dealer Service Instructions for: Safety Recall F05 Antilock Brake System Control Module Please remove and discard from your files all previous copies of Safety Recall F05 (dated June 2006). This revision has additional parts information to clarify the ABS Control Module application for Dodge Ram Mega Cab models. Models 2006 (DR) Dodge Ram Pickup Truck (1500 Series) 2006 (DH) Dodge Ram Pickup Truck (1500 Mega Cab & 2500 Series) 2006 (D1) Dodge Ram Pickup Truck (3500 Series) 2006 (ND) Dodge Dakota Pickup Truck NOTE: This recall applies only to the above vehicles equipped with a Four-Wheel Antilock Brake System (sales code BGK or BRT) built from September 12, 2005 through December 11, 2005 (MDH 091221 through 121114). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Antilock Brake System (ABS) control module on about 37,900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be replaced and initialized with the StarSCAN tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 78 Parts Information The ABS module part number for the vehicle to be serviced may also be determined as follows: > From the DealerCONNECT "Service" tab, in the "Write Up" box under "Vehicle Information Plus" select "Single VIN Inquiry." Enter the VIN and odometer reading and click the "View" button. Select the Recall Tab and the recall part number will be displayed. > From the DealerCONNECT "Service" tab, select "Global Recall System." Click on the recall number, select "List by VIN" from drop down menu, and click the "Submit" button. A list of incomplete involved vehicles for your dealer will be generated. NOTE: If F05 is not listed, there are no involved vehicles assigned to your dealer code. Special Tools Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 79 The existing special tools shown will be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 80 schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: The StarSCAN must be used to initialize the new ABS control module after installation. 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Clean the ABS control module to prevent dirt from falling into the hydraulic control unit when the ABS control module is removed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 81 NOTE: The ABS control module is located next to the battery on DR/DH and D1 models (Dodge Ram Truck) (Figure 1). The ABS control module is located under the Power Distribution Center on ND models (Dodge Dakota) (Figure 2). 3. Pull up on the ABS control module harness connector lock and disconnect the wiring from the ABS control module (Figure 1). 4. Using a T-20 Torx driver, remove and discard the ABS control module mounting screws (Figure 3). 5. Remove and discard the ABS control module from the Hydraulic Control Unit (HCU). 6. Install the new ABS control module onto the HCU. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 82 7. Install the new ABS control module mounting screws included in the kit (Figure 4). Tighten the screws to 35 in. lbs. (4 N.m). 8. Connect the wiring harness to the ABS control module and push down on the connector lock to secure the connector. 9. Connect the negative battery cable(s) to the negative battery terminal(s). 10. Connect the StarSCAN to the data link connector located under the steering column. 11. Place the ignition key in the "RUN" position (engine not running). 12. Push the power button on the StarSCAN and wait for the scan tool to "power up." 13. From the Home Screen, select "ECU¡ VIEW". 14. Select "ABS Anti-lock Brakes / Electronic Stability". 15. Select "Misc. Functions" on the screen. 16. Select "Initialize ECU" and then press the "START" button. 17. Press the "NEXT" button. 18. Follow the scan tool screen prompts to complete the ECU initializing process. 19. Select the "BACK" button twice. 20. After completing ABS control module reprogramming clear all fault codes using the following procedure: a. Return to the "Main Menu" (Home Page) and select "System View". b. Select "All DTC's" c. Select "Clear All Stored DTC's" and then follow the screen prompts. 21. Remove the StarSCAN from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 83 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA06V038000 > Feb > 06 > Recall 06V038000: ABS ECU Replacement Electronic Brake Control Module: Recalls Recall 06V038000: ABS ECU Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2006 Dodge/Ram 2006 Mitsubishi/Raider 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V038000 MFG'S REPORT DATE: February 07, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 39274 SUMMARY: On certain pickup trucks equipped with four-wheel Antilock Brake Systems (ABS), The ABS Electronic Control Unit (ECU) may cause a loss of front to rear brake balance, and the rear brakes could lock up prematurely during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the ABS ECU. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F05. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement Technical Service Bulletin # F05 Date: 060701 Recall - ABS Control Module Replacement Revised July 2006 Dealer Service Instructions for: Safety Recall F05 Antilock Brake System Control Module Please remove and discard from your files all previous copies of Safety Recall F05 (dated June 2006). This revision has additional parts information to clarify the ABS Control Module application for Dodge Ram Mega Cab models. Models 2006 (DR) Dodge Ram Pickup Truck (1500 Series) 2006 (DH) Dodge Ram Pickup Truck (1500 Mega Cab & 2500 Series) 2006 (D1) Dodge Ram Pickup Truck (3500 Series) 2006 (ND) Dodge Dakota Pickup Truck NOTE: This recall applies only to the above vehicles equipped with a Four-Wheel Antilock Brake System (sales code BGK or BRT) built from September 12, 2005 through December 11, 2005 (MDH 091221 through 121114). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Antilock Brake System (ABS) control module on about 37,900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be replaced and initialized with the StarSCAN tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 93 Parts Information The ABS module part number for the vehicle to be serviced may also be determined as follows: > From the DealerCONNECT "Service" tab, in the "Write Up" box under "Vehicle Information Plus" select "Single VIN Inquiry." Enter the VIN and odometer reading and click the "View" button. Select the Recall Tab and the recall part number will be displayed. > From the DealerCONNECT "Service" tab, select "Global Recall System." Click on the recall number, select "List by VIN" from drop down menu, and click the "Submit" button. A list of incomplete involved vehicles for your dealer will be generated. NOTE: If F05 is not listed, there are no involved vehicles assigned to your dealer code. Special Tools Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 94 The existing special tools shown will be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 95 schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: The StarSCAN must be used to initialize the new ABS control module after installation. 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Clean the ABS control module to prevent dirt from falling into the hydraulic control unit when the ABS control module is removed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 96 NOTE: The ABS control module is located next to the battery on DR/DH and D1 models (Dodge Ram Truck) (Figure 1). The ABS control module is located under the Power Distribution Center on ND models (Dodge Dakota) (Figure 2). 3. Pull up on the ABS control module harness connector lock and disconnect the wiring from the ABS control module (Figure 1). 4. Using a T-20 Torx driver, remove and discard the ABS control module mounting screws (Figure 3). 5. Remove and discard the ABS control module from the Hydraulic Control Unit (HCU). 6. Install the new ABS control module onto the HCU. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 97 7. Install the new ABS control module mounting screws included in the kit (Figure 4). Tighten the screws to 35 in. lbs. (4 N.m). 8. Connect the wiring harness to the ABS control module and push down on the connector lock to secure the connector. 9. Connect the negative battery cable(s) to the negative battery terminal(s). 10. Connect the StarSCAN to the data link connector located under the steering column. 11. Place the ignition key in the "RUN" position (engine not running). 12. Push the power button on the StarSCAN and wait for the scan tool to "power up." 13. From the Home Screen, select "ECU¡ VIEW". 14. Select "ABS Anti-lock Brakes / Electronic Stability". 15. Select "Misc. Functions" on the screen. 16. Select "Initialize ECU" and then press the "START" button. 17. Press the "NEXT" button. 18. Follow the scan tool screen prompts to complete the ECU initializing process. 19. Select the "BACK" button twice. 20. After completing ABS control module reprogramming clear all fault codes using the following procedure: a. Return to the "Main Menu" (Home Page) and select "System View". b. Select "All DTC's" c. Select "Clear All Stored DTC's" and then follow the screen prompts. 21. Remove the StarSCAN from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 98 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA06V038000 > Feb > 06 > Recall 06V038000: ABS ECU Replacement Electronic Brake Control Module: All Technical Service Bulletins Recall 06V038000: ABS ECU Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2006 Dodge/Ram 2006 Mitsubishi/Raider 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V038000 MFG'S REPORT DATE: February 07, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 39274 SUMMARY: On certain pickup trucks equipped with four-wheel Antilock Brake Systems (ABS), The ABS Electronic Control Unit (ECU) may cause a loss of front to rear brake balance, and the rear brakes could lock up prematurely during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the ABS ECU. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F05. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 103 Electronic Brake Control Module: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 104 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 105 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 106 Electronic Brake Control Module: Diagrams Module - Anti-lock Brakes (RWAL) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 107 Module - Anti-lock Brakes (AWAL) Module - Brake Provision Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 108 Electronic Brake Control Module: Description and Operation The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 109 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 N.m (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Instruments - Overhead Average Fuel Economy Display Fuel Distance/Mileage Module: Technical Service Bulletins Instruments - Overhead Average Fuel Economy Display NUMBER: 08-020-06 GROUP: Electrical DATE: May 5, 2006 SUBJECT: Overhead Console Average Fuel Economy Display MODELS: 2006 (DR/DH) Ram Truck Discussion: On 2006 vehicles equipped with a Compass Mini Trip Computer (CMTC), the average fuel economy displayed after a reset has been changed. On previous models when the CMTC average fuel economy was reset by the customer, the new calculation was based on the fuel usage at the time the reset was activated. In this situation, if a customer was travelling up hill or accelerating, the display would show a very low average fuel economy and it could take considerable time for the display to reflect an accurate average fuel economy display. Conversely, if a customer was travelling down hill and was off the accelerator, the display would show very high fuel economy. On 2006 vehicles, the calculation has been changed to use the last displayed average fuel economy as a starting point for the calculation after a reset. The average fuel economy will then be adjusted from that point. If the display read 21.6 MPG at the time the reset was activated, the new display will start a 21.6 MPG and would change from that point depending on the current fuel usage. This was done to eliminate the extreme variations caused by very high or low fuel usage at the time of the reset. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 119 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 123 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 127 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 132 Battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 133 Power Distribution Module: Diagrams Module - Totally Integrated Power C1 Module - Totally Integrated Power C10 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 134 Module - Totally Integrated Power C2 Module - Totally Integrated Power C3 Module - Totally Integrated Power C4 Module - Totally Integrated Power C5 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 135 Module - Totally Integrated Power C6 Module - Totally Integrated Power C7 Module - Totally Integrated Power C8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 136 Module - Totally Integrated Power C9 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 139 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 140 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 143 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 144 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 145 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 152 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 153 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 154 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 155 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 156 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 157 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 158 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 159 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 160 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 161 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: Customer Interest Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 172 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 173 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 174 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: All Technical Service Bulletins Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 180 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 181 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 182 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 188 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 189 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 195 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 196 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: Customer Interest Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 207 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 208 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 209 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 210 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: All Technical Service Bulletins Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 216 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 217 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 218 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 219 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 224 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 225 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 226 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 232 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 233 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 234 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 235 Engine Control Module: Locations Right Rear Engine Compartment - NGC Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 236 Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 239 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 240 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 241 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 242 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 243 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 244 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 249 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 250 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 251 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 253 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 254 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 256 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 258 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Engine Control Module: Connector Views Module - Powertrain Control C1 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Module - Powertrain Control C2 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Module - Powertrain Control C3 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 262 Module - Powertrain Control C4 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 263 Engine Control Module: Description and Operation The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 264 engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 265 - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 266 by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 267 - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming Engine Control Module: Service and Repair PCM/ECM/SKREEM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (such as relays and solenoids) and shorted circuits (such as pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE PCM/ECM/SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, the GateWay module (on SRT10 vehicles with a hybrid bus only) and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM Replaced, ECM Replaced, WCM Replaced, or GateWay Replaced under Miscellaneous Functions for the WCM/Wireless Control Module menu item as appropriate. NOTE: - Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. - If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. - Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for Program Ignition Keys or Key FOBs under Miscellaneous Functions for the WCM/Wireless Control Module menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 270 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 271 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 275 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 276 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 277 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Description and Operation Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 287 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 288 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 289 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 290 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 291 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 292 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 293 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 294 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 295 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 296 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 297 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 298 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 299 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 300 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 301 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 302 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 303 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 304 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 305 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 306 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 307 Fuel Pump Relay: Description and Operation A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 311 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 312 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 313 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The 5.7L is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches to the spark plugs. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Ignition Coils - 2 Knock Sensors - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag Control Module: Recalls Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag Control Module: All Technical Service Bulletins Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 335 Air Bag Control Module: Locations Front Center Body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 336 Left Side Body - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 337 Left Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 338 Air Bag Control Module: Diagrams Module - Occupant Restraint Controller C1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 339 Module - Occupant Restraint Controller C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 344 Relay - Starter Motor (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 345 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 346 Starter Relay: Testing and Inspection The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12 V battery to terminals 85 an 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch, Transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 347 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover (2) from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition ON voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 353 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift and shift points, depending on the present operating conditions and driver demand. This is possible through control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the Quick Learn Procedure must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 354 By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the Monitors display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE 545RFE SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 355 Part 1 Part 2 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 360 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 363 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 370 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 375 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 376 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 378 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 379 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description Transmission Control System Relay: Description and Operation Description DESCRIPTION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description > Page 382 Transmission Control System Relay: Description and Operation Operation OPERATION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 387 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 391 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 396 Wiper Relay: Description and Operation Dodge Ram 2006-2009, does not use a wiper relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 402 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 403 Switch - Adjustable Pedals (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 404 Pedal Positioning Switch: Service and Repair SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 408 Remote Switch: Diagrams Switch-Remote Radio - Left Switch-Remote Radio - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 409 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 410 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams refer to appropriate wiring information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 411 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 416 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 417 Switch - Adjustable Pedals (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 418 Pedal Positioning Switch: Service and Repair SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 422 Right Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 423 Power Door Lock Switch: Diagrams Switch-Door Lock - Passenger Switch-Window/Door Lock - Driver C1 Switch-Window/Door Lock - Driver C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 424 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock Power Door Lock Switch: Testing and Inspection Switch - Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock > Page 427 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock > Page 428 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch - Power Lock Power Door Lock Switch: Service and Repair Switch - Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch - Power Lock > Page 431 Power Door Lock Switch: Service and Repair Switch - Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 435 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt - Driver Switch-Seat - Driver Switch-Seat - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 442 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 443 Power Seat Switch: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If OK, refer to Power Seat Track/Testing and Inspection. If not OK, replace the inoperative power seat switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 444 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 448 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 449 Seat Heater Switch: Diagrams Switch-Heated Seat - Driver Switch-Heated Seat - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 450 Seat Heater Switch: Description and Operation Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/ module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 451 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Headliner Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 455 Switch - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 456 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination pushbutton and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 457 Sunroof / Moonroof Switch: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 462 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 463 Sensor - Brake Fluid Level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 467 Switch - Parking Brake Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 468 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Refer to appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 469 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an inoperative park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 470 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 474 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 475 Rear Chassis Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 476 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed - ABS - Left Front Sensor-Wheel Speed - ABS - Rear Sensor-Wheel Speed - ABS - Right Front Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 477 Wheel Speed Sensor: Description and Operation SENSOR- WHEEL SPEED-ABS-FRONT DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal. ^ Number of windings in the sensor; more windings provide a stronger signal. ^ Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be. ^ Distance (3) air gap between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a Rolls Test on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear Wheel Speed Sensor: Testing and Inspection Rear REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear > Page 480 Wheel Speed Sensor: Testing and Inspection Tone Wheel-Rear WHEEL-TONE REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The ABM monitors the system inputs and outputs circuits to verify the system is operating properly. If the ABM senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool must be used to diagnose the Antilock Brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front SENSOR- WHEEL SPEED-ABS-FRONT REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 483 Wheel Speed Sensor: Service and Repair Rear SENSOR-WHEEL SPEED-ABS-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 489 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 490 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control - Left Switch-Speed Control - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 495 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 496 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 503 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 505 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 506 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 507 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 508 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 509 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 510 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 511 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 512 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 513 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 514 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 515 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 516 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 517 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 518 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 519 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 521 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 522 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 523 Switch - Oil Pressure (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 530 Sensor - Engine Oil Temperature (5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 531 Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. Oil Temperature Sensor Tests (Part 1) Oil Temperature Sensor Tests (Part 2) 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 536 Sensor - Ambient Air Temperature Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 537 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 538 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation, refer to testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 539 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations HVAC Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 543 Sensor - Evaporator Temperature Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 544 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the A/C evaporator. The probe (1) for evaporator temperature sensor is attached to the evaporator coil fins. The wire lead (2) for evaporator temperature sensor is routed through an opening at the back of the HVAC housing and the connector (3) is attached to the HVAC wire harness. The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 545 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Remove the wire lead for the evaporator temperature sensor (2) from the retainer located on the HVAC housing (1) and disconnect the sensor connector from the HVAC wire harness (3). 3. Remove the lower half of the HVAC housing from the upper half of the HVAC housing to gain access to the A/C evaporator. 4. Carefully remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2). 5. Remove the wire lead of the evaporator temperature sensor (3) from the upper half of the HVAC housing (4). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 546 1. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator (2). 2. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing (4). 3. Assemble the HVAC housing. 4. Install the wire lead of the evaporator temperature sensor (2) to the retainer located on the HVAC housing (1) and connect the sensor connector to the HVAC wire harness (3). 5. Install the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer - A/C Pressure (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 550 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10 ° C (50° F) due to the pressure/ temperature relationship of the refrigerant. The A/C pressure transducer input to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 551 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro- Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Controller Area Network (CAN) data bus. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic message inputs or outputs used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit Fuel Gauge Sender: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit > Page 560 Fuel Gauge Sender: Locations Fuel Pump The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 563 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 564 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 565 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 566 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 567 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 568 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 569 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 570 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 571 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 572 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 573 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 574 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 575 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 576 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 577 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 578 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 579 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 580 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 581 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 582 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 583 Fuel Gauge Sender: Description and Operation The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 584 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 591 Switch - Parking Brake Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 592 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Refer to appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 593 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an inoperative park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 594 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 600 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 601 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 602 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 603 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 604 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 605 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 606 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 607 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 608 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 609 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 610 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 611 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 612 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 613 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 614 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 615 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 616 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 617 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 618 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 619 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 620 Switch - Backup Lamp (M/T 5.7L HD/Diesel M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 621 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if inoperative or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 622 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the inoperative backup lamp switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 626 Switch - Stop Lamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 627 Brake Light Switch: Description and Operation The brake lamp switch (2) is a three circuit, springloaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, inoperative, or removed from its mounting position for any reason, it must be replaced with a new unit. The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned On and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch is diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 628 Brake Light Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the inoperative brake lamp switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 629 Brake Light Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. 6. Discard the removed brake lamp switch. INSTALLATION 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 630 seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 634 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 635 Switch - Multifuction Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 636 Combination Switch: Description and Operation The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (On and Off) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, low speed or high speed; and, an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is inoperative, or if the switch is damaged, the entire switch must be replaced as a unit. The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system Off. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned off, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected low or high beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the right turn signal circuitry, and, downward to activate the left turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 637 the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. When a turn signal is activated, the multifunction switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the washer mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the Off position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or deenergizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 638 Combination Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi- Function Switch Tests table. 4. If the switch fails any of the tests, replace the inoperative multi-function switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 639 Combination Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 640 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. INSTALLATION 1. Slide the multi-function switch (1) into the multifunction switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 641 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro- Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Controller Area Network (CAN) data bus. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic message inputs or outputs used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 648 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 652 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 653 Switch - Headlamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 654 Headlamp Switch: Description and Operation The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three detent position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary "Push" function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. On models with optional fog lamps the rotary knob also has the text "PUSH" and an International Control and Display Symbol icon for Front Fog Light applied to it. The thumbwheel is also plastic and knurled. The cargo lamp push button is plastic with a smooth finish and the text "CARGO" applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if inoperative or damaged, it must be replaced. The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. - Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or deenergizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned On. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome defeat, dome on, parade/funeral mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and/or the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 655 The headlamp switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to and PWM processing of the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 656 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the cluster bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the wire harness connector from the back of the headlamp switch. Headlamp Part 1 Headlamp Part 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 657 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the inoperative headlamp switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 658 Headlamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. INSTALLATION 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 N.m (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Switch - Horn Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 662 Horn Switch: Description and Operation The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 663 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 670 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 671 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 672 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 673 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 677 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 678 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 679 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 683 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 684 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 685 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 686 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL POSITION 1. Disconnect switch 2wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed-Continuity - Pedal Released-No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 693 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 694 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 699 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 700 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 701 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 702 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 703 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit Fuel Level Sensor: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit > Page 708 Fuel Level Sensor: Locations Fuel Pump Module The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 709 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 710 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 715 Intake Air Temperature Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 716 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 717 Sensor - Intake Air Temperature (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 718 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5 volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 719 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 720 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 724 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 725 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 726 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 727 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 728 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 733 Manifold Pressure/Vacuum Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 734 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 735 Sensor - Map (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 736 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 737 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 738 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counterclockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 739 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 747 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 748 Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 749 Oxygen Sensor: Diagrams Sensor-Oxygen - Left Front (3.7L/5.7L) Sensor-Oxygen - Left Rear (3.7L/5.7L LD) Sensor-Oxygen - Left Rear (4.7L/5.7L HD) Sensor-Oxygen - Right Front (3.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 750 Sensor-Oxygen - Right Rear (3.7L/5.7L LD) Sensor-Oxygen - Right Rear (4.7L/5.7L HD) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 751 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 752 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 753 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 757 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 758 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 759 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 763 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 768 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 769 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 770 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 773 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 774 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 775 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 780 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 781 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 783 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 784 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 790 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 793 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 794 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 795 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 796 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 798 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 799 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 805 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 806 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 807 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 808 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 812 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 817 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 818 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 819 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 820 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 825 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 826 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 827 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 828 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 829 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 834 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 838 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 839 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 840 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 841 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 842 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 847 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 848 Switch - Passenger Airbag On/Off Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 849 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The "Off" position nomenclature of the switch is illuminated and visible only when that switch position is selected. The "On" position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off nomenclature), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the Off indicator will be extinguished and the passenger airbag is enabled. The Off indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ORC provides a ground input to the Off indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ORC, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 850 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: A passenger airbag on/off switch is used only on standard cab models equipped with dual front airbags. Quad cab and mega cab models have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 851 following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 855 Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 856 Left Side Body - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 857 Standard Cab Right Side Body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 858 Left Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 859 Right Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 860 Impact Sensor: Diagrams Sensor-Front Impact - Left Sensor-Front Impact - Right Sensor-Side Impact - Left 1 Sensor-Side Impact - Right 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 861 Impact Sensor: Description and Operation FRONT Two front impact sensors (1) are used on this model, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires the use of a diagnostic scan tool. Refer to Trouble Code Diagnostic Charts. SIDE Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain airbags, one each for the left and right sides of the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 862 vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Occupant Restraint Controller (ORC). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires the use of a diagnostic scan tool. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE FRONT IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. INSTALLATION 1. Position the right or left front impact sensor (3) into the engine compartment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 865 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 N.m (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 866 Impact Sensor: Service and Repair Side WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. SIDE - STANDARD CAB REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 867 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. SIDE - QUAD CAB REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 868 INSTALLATION 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. SIDE - MEGA CAB REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 869 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 873 Seat Belt Buckle Switch: Description and Operation All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electromechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The driver side seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams Sensor-Seat Track Position - Driver Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 877 Seat Sensor/Switch: Description and Operation The seat track position sensor (2) is a Hall Effect-type sensor used on some models. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if faulty or damaged, the entire sensor must be replaced. The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the CAN data bus to illuminate the airbag indicator in the instrument cluster. For proper diagnosis of the seat track position sensor, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 878 Seat Sensor/Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. INSTALLATION 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 883 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 884 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 885 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 893 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 899 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 900 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 901 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 907 Sensor - Line Pressure (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Description and Operation 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 910 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE DESCRIPTION The line pressure sensor (2) is mounted on the top of the valve body, next to the pressure control solenoid 0). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 911 Fluid Pressure Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Line Pressure SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 912 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 915 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 916 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 917 Fluid Pressure Sensor/Switch: Service and Repair 45RFE/545RFE Automatic Transmission Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 918 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Sensor-Line Pressure SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pres sure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 919 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 923 Switch - Tow/Haul Overdrive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Switch: Description and Operation 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 926 Overdrive Switch: Description and Operation 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 929 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 930 Overdrive Switch: Service and Repair 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 931 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 935 Switch - Clutch Interlock (M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 940 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 941 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 942 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 945 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 946 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 947 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 951 Transmission Speed Sensor: Diagrams Sensor - Input Speed (RFE/RLE) Sensor - Output Speed (RFE/RLE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Speed Sensor: Description and Operation 42RLE Automatic Transmission Sensor Output Speed SENSOR OUTPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor Input Speed SENSOR INPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 954 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 955 Transmission Speed Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Speed Sensor: Service and Repair 42RLE Automatic Transmission Sensor Input Speed SENSOR INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor (1) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor Output Speed SENSOR OUTPUT SPEED REMOVAL 1. Raise vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 958 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor(2). NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor (2) from the transmission case. INSTALLATION 1. Install the output speed sensor (2) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 959 Transmission Speed Sensor: Service and Repair 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the trans mission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor-Output Speed SENSOR-OUTPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 960 3. Remove the wiring connector from the output speed sensor(1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Temperature Sensor/Switch: Description and Operation 42RLE Automatic Transmission Sensor Transmission Range SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Sensor Transmission Temperature SENSOR TRANSMISSION TEMPERATURE DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 965 The transmission temperature sensor (2) is located in the transmission range sensor (1) and communicates transmission sump temperature to the TCM. OPERATION The transmission range sensor (TRS) has an integrated thermistor that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The TCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 966 Transmission Temperature Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Temperature SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 967 Transmission Temperature Sensor/Switch: Service and Repair SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 968 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Switch - Power Sliding Backlite (Quad Cab/Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 973 Heated Glass Element Switch: Description and Operation The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to On position a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes as long as the ignition switch is the Run position. After the initial time interval has expired, if the rear window defogger switch is turned on again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than Run, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 977 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 978 Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 979 Right Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 980 Left Rear Door (Right Side Similar) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 981 Power Window Switch: Diagrams Switch-Power Window - Left Rear Switch-Power Window - Passenger Switch-Power Window - Right Rear Switch-Window/Door Lock - Driver C1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 982 Switch-Window/Door Lock - Driver C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 983 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LED's are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LED's are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch refer to testing for service procedures. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to Power Windows/Testing and Inspection. If not OK, replace the faulty switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 984 Power Window Switch: Service and Repair FRONT PASSENGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 989 Switch - Washer Fluid Level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 990 Washer Fluid Level Switch: Description and Operation The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Controller Area Network (CAN) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT10 and diesel engines) or left (SRT10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch circuits may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the TIPM, the CAN data bus, or the electronic message inputs to or outputs from the instrument cluster and the TIPM that control the operation of the washer fluid visual and audible indications. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the TIPM, the CAN data bus or the electronic message inputs and outputs related to the washer fluid indicator requires the use of diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 991 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the right headlamp and dash wire harness 4. connector for the washer fluid level switch 3. from the switch connector receptacle. 4. Using a trim stick or another suitable wide flatbladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2) Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (3) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the right headlamp and dash wire harness 4. connector to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application Alignment: Customer Interest Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 1001 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 1002 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application Alignment: All Technical Service Bulletins Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 1008 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 1009 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1010 Alignment: By Symptom Technical Service Bulletin # 02-001-07A Date: 070331 Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1011 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1012 For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 02-001-07A Date: 070331 Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1013 This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1014 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1015 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 02-001-07A Date: 070331 Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1016 MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1017 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 1018 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1019 Alignment: Specifications ALIGNMENT NOTE: All alignment specifications are in degrees. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1020 SPECIFICATIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1021 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION ^ CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns ^ CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire ^ TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification causes unstable steering, uneven tire wear and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment ^ THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1022 Alignment: Testing and Inspection PREALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Road test the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1023 Alignment: Service and Repair CAMBER, CASTER AND TOE ADJUSTMENT AND CURB HEIGHT MEASUREMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front of rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1024 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheels with the front wheels in the straight-ahead position. 2. Loosened the tie rod jam nut (1). Note: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm ( 94 ft lbs ). 5. Verify the specifications. 6. Turn off engine. CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full if fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring weak, Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1025 1. Front - On each side of the vehicle measure the distance from the center of the rear lower control arm bolt (1) to the ground (2). Record the measurement. Next measure the distance from the spindle center (3) to the ground (4). Recod measurement. 2. Take the two measurements and subtract them to get the ride height specification. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1026 3. Rear 4X2 - On each side of the vehicle, measure the distance at the axle tube (1) to the jounce bumper flange (2). 4. Rear 4X4 - On each side of the vehicle, measure the distance at the jounce pad welded to the axle tube (1) to the jounce bumper flange (2). 5. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1031 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1032 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1036 Idle Speed: Description and Operation 5.7L: A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Fig. 1 AIR CLEANER COVER Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1041 Fig. 2 AIR CLEANER HOUSING 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips (5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4 Nm (40 inch lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1042 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1051 right front side of the engine block (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1052 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1053 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1054 Firing Order ......................................................................................................................................... ......................................................... 1-8-4-3-6-5-7-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plugs Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1063 Spark Plug: Mechanical Specifications Gap ...................................................................................................................................................... ................................................... 0.045 in. (1.14mm) Torque ................................................................................................................................................. ................................................... 13 ft. lbs. (18 N-m) Torque critical design. Do not exceed 15 ft. lbs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1064 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1065 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L engines. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. This is especially true when plugs are equipped with tapered seats. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation REMOVAL Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary. 5. Inspect spark plug condition. INSTALLATION NOTE: The 4.7L is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 27 N.m (20 ft.lbs.). 3.7L & 4.7L. 3. The 5.7L is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. torque. Tighten spark plugs to 18 N.m (13 ft.lbs). NOTE: 5.7L does not use an O-ring 4. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 5. Install ignition coil(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 1068 Spark Plug: Service and Repair Cleaning CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1072 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks-5.7L Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1079 Drive Belt: Testing and Inspection BELT-DRIVE DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS NOTE: 5.9L Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. ACCESSORY DRIVE BELT DIAGNOSIS CHART (part 1) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1080 ACCESSORY DRIVE BELT DIAGNOSIS CHART (part 2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1081 ACCESSORY DRIVE BELT DIAGNOSIS CHART (part 3) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1082 Drive Belt: Service and Repair BELT-DRIVE REMOVAL 5.7L ENGINE The 5.7L engine accessory drive system consists of: A/C Compressor or Idler Pulley (1) - Fan Drive Pulley (2) - Power Steering Pump (3) - Crankshaft Pulley (4) - Idler Assembly (5) - Tensioner Assembly (6) - Accessory Drive Belt (7) - Generator (8) - Idler Pulley (9) 1. Remove the air intake tube between intake manifold and air filter assembly. 2. Insert a suitable square drive ratchet into the square hole on belt tensioner arm. 3. Release the belt tension by rotating the tensioner clockwise. Rotate belt tensioner until belt can be removed from pulleys. 4. Remove belt. 5. Gently release tensioner. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1083 The 5.7L engine accessory drive system consists of: A/C Compressor or Idler Pulley (1) - Fan Drive Pulley (2) - Power Steering Pump (3) - Crankshaft Pulley (4) - Idler Assembly (5) - Tensioner Assembly (6) - Accessory Drive Belt (7) - Generator (8) - Idler Pulley (9) NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Position the drive belt over all pulleys except for the water pump pulley. 2. Rotate tensioner clockwise and slip the belt over the water pump pulley. 3. Gently release tensioner. 4. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Fig. 1 AIR CLEANER COVER Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1089 Fig. 2 AIR CLEANER HOUSING 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips (5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4 Nm (40 inch lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1090 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a cabin air filter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement Technical Service Bulletin # E16 Date: 051001 Campaign - A/T 545RFE Cooler Return Filter Replacement October, 2005 Dealer Service Instructions for: Customer Satisfaction Notification E16 Transmission Cooler Return Filter Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin # 21-016-05 is cancelled for 2006 vehicles. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2006 (DR) Dodge Ram 1500 2006 (DH) Dodge Ram 2500 2006 (D1) Dodge Ram 3500 2006 (HB) Dodge Durango 2006 (ND) Dodge Dakota 2006 (KJ) Jeep Liberty 2006 (WK) Jeep Grand Cherokee 2006 (XK) Jeep Commander NOTE: This notification applies only to the above vehicles equipped with a 545RFE automatic transmission (sales code DGO) and a transmission built date code from TJ1015 through TJ2315. Many of the vehicles built within this date range were repaired before shipment to dealers and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The transmission on about 17,200 of the above vehicles may experience a delayed engagement when the shifter is placed into gear after the engine has been off for more than 12 hours. Repair The internal transmission cooler return filter must be replaced. Parts Information Special Tool Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1102 The Special Tool is required to perform this recall: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1103 1. Raise vehicle on a hoist. 2. Remove transmission skid plate (if so equipped). 3. Place a drain container with a large opening, under transmission oil pan. 4. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain, and then remove the oil pan. 5. Clean the oil pan and wipe the magnet with a clean dry lint-free cloth. 6. Clean transmission case oil pan surface using a plastic scraper. Caution: Be careful not to scratch the sealing surface. 7. Remove the round transmission cooler filter using an oil filter wrench (special tool 8321). (Figure 1) Remove the filter connector nipple from the transmission if necessary. Discard both parts. 8. Install new cooler return filter to the transmission and tighten the filter to 125 in lbs (14 N.m) (Fig. 1). 9. Apply a 1/8" bead of Mopar ATF-RTV Silicone Adhesive sealant to the transmission oil pan. 10. Install transmission oil pan and tighten oil pan bolts to 105 in lbs (12 N.m). 11. Install transmission skid plate (if so equipped). 12. Pour seven quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening. 13. Start engine and allow it to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position. 14. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to second hole from the tip of the dipstick (full cold transmission). The transmission temperature should be at about 70°F. CAUTION: DO NOT OVERFILL. 15. Recheck the fluid level after the transmission has reached normal operating temperature (180°F.). Adjust fluid level as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1104 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: Customer Interest A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1110 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1111 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1112 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1117 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: All Technical Service Bulletins A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1123 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1124 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1125 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement Technical Service Bulletin # E16 Date: 051001 Campaign - A/T 545RFE Cooler Return Filter Replacement October, 2005 Dealer Service Instructions for: Customer Satisfaction Notification E16 Transmission Cooler Return Filter Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin # 21-016-05 is cancelled for 2006 vehicles. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2006 (DR) Dodge Ram 1500 2006 (DH) Dodge Ram 2500 2006 (D1) Dodge Ram 3500 2006 (HB) Dodge Durango 2006 (ND) Dodge Dakota 2006 (KJ) Jeep Liberty 2006 (WK) Jeep Grand Cherokee 2006 (XK) Jeep Commander NOTE: This notification applies only to the above vehicles equipped with a 545RFE automatic transmission (sales code DGO) and a transmission built date code from TJ1015 through TJ2315. Many of the vehicles built within this date range were repaired before shipment to dealers and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The transmission on about 17,200 of the above vehicles may experience a delayed engagement when the shifter is placed into gear after the engine has been off for more than 12 hours. Repair The internal transmission cooler return filter must be replaced. Parts Information Special Tool Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1130 The Special Tool is required to perform this recall: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1131 1. Raise vehicle on a hoist. 2. Remove transmission skid plate (if so equipped). 3. Place a drain container with a large opening, under transmission oil pan. 4. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain, and then remove the oil pan. 5. Clean the oil pan and wipe the magnet with a clean dry lint-free cloth. 6. Clean transmission case oil pan surface using a plastic scraper. Caution: Be careful not to scratch the sealing surface. 7. Remove the round transmission cooler filter using an oil filter wrench (special tool 8321). (Figure 1) Remove the filter connector nipple from the transmission if necessary. Discard both parts. 8. Install new cooler return filter to the transmission and tighten the filter to 125 in lbs (14 N.m) (Fig. 1). 9. Apply a 1/8" bead of Mopar ATF-RTV Silicone Adhesive sealant to the transmission oil pan. 10. Install transmission oil pan and tighten oil pan bolts to 105 in lbs (12 N.m). 11. Install transmission skid plate (if so equipped). 12. Pour seven quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening. 13. Start engine and allow it to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position. 14. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to second hole from the tip of the dipstick (full cold transmission). The transmission temperature should be at about 70°F. CAUTION: DO NOT OVERFILL. 15. Recheck the fluid level after the transmission has reached normal operating temperature (180°F.). Adjust fluid level as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1132 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1137 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: All Technical Service Bulletins A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1143 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1144 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 1145 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 1150 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement Technical Service Bulletin # E16 Date: 051001 Campaign - A/T 545RFE Cooler Return Filter Replacement October, 2005 Dealer Service Instructions for: Customer Satisfaction Notification E16 Transmission Cooler Return Filter Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin # 21-016-05 is cancelled for 2006 vehicles. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2006 (DR) Dodge Ram 1500 2006 (DH) Dodge Ram 2500 2006 (D1) Dodge Ram 3500 2006 (HB) Dodge Durango 2006 (ND) Dodge Dakota 2006 (KJ) Jeep Liberty 2006 (WK) Jeep Grand Cherokee 2006 (XK) Jeep Commander NOTE: This notification applies only to the above vehicles equipped with a 545RFE automatic transmission (sales code DGO) and a transmission built date code from TJ1015 through TJ2315. Many of the vehicles built within this date range were repaired before shipment to dealers and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The transmission on about 17,200 of the above vehicles may experience a delayed engagement when the shifter is placed into gear after the engine has been off for more than 12 hours. Repair The internal transmission cooler return filter must be replaced. Parts Information Special Tool Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1156 The Special Tool is required to perform this recall: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1157 1. Raise vehicle on a hoist. 2. Remove transmission skid plate (if so equipped). 3. Place a drain container with a large opening, under transmission oil pan. 4. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain, and then remove the oil pan. 5. Clean the oil pan and wipe the magnet with a clean dry lint-free cloth. 6. Clean transmission case oil pan surface using a plastic scraper. Caution: Be careful not to scratch the sealing surface. 7. Remove the round transmission cooler filter using an oil filter wrench (special tool 8321). (Figure 1) Remove the filter connector nipple from the transmission if necessary. Discard both parts. 8. Install new cooler return filter to the transmission and tighten the filter to 125 in lbs (14 N.m) (Fig. 1). 9. Apply a 1/8" bead of Mopar ATF-RTV Silicone Adhesive sealant to the transmission oil pan. 10. Install transmission oil pan and tighten oil pan bolts to 105 in lbs (12 N.m). 11. Install transmission skid plate (if so equipped). 12. Pour seven quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening. 13. Start engine and allow it to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position. 14. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to second hole from the tip of the dipstick (full cold transmission). The transmission temperature should be at about 70°F. CAUTION: DO NOT OVERFILL. 15. Recheck the fluid level after the transmission has reached normal operating temperature (180°F.). Adjust fluid level as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 1158 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 42RLE 4 Speed Fluid Filter - A/T: Service and Repair 42RLE 4 Speed FLUID/FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF+4, Automatic Transmission Fluid, should be used in the transmission sump. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transmission is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transmission oil pan. NOTE: One of the oil pan bolts (5) has a sealing patch applied from the factory. Separate this bolt for reuse. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and o-ring on bottom of the valve body and tighten retaining screws to 5 Nm (45 inch lbs.). NOTE: Before installing the oil pan bolt (5) in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits, it will be necessary to replenish the sealing patch on the bolt using Mopar Lock & Seal Adhesive. 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 20 Nm (14.5 ft. lbs.). 5. Pour four quarts of Mopar ATF+4, Automatic Transmission Fluid, through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick. 8. Recheck the fluid level after the transmission has reached normal operating temperature, 82°C (180°F). 9. To prevent dirt from entering transmission, make certain that dipstick is fully seated into the dipstick opening. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 42RLE 4 Speed > Page 1161 Fluid Filter - A/T: Service and Repair 45RFE 4 Speed/545RFE 5 Speed FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to testing. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 42RLE 4 Speed > Page 1162 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (7 ft. lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR ATF +4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Locations > Page 1170 Fuel Pump Pickup Filter: Service and Repair FILTER - INLET REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Remove filter by carefully prying 2 lock tabs (2) at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. 3. Install fuel tank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil Service Oil Filter: Service and Repair Engine Oil Service ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to Service Precautions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil Service > Page 1175 Oil Filter: Service and Repair Removal and Installation FILTER - ENGINE OIL REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. DaimlerChrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter (3). 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket (2) with engine oil. 2. Thread filter (3) onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions WARNING: - THE A/C SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE A/C REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION AND DEATH. - THE EVAPORATION RATE OF R-134A REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134A SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES UP TO 145 KILOPASCALS (21 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. CAUTION - Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. - Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. - Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line Hose/Line HVAC: Description and Operation Coupler-Refrigerant Line Spring-lock type refrigerant line couplers (1 and 4) are used to connect the A/C suction line (6) to the A/C accumulator (5) and, the A/C accumulator and the A/C liquid line to the A/C evaporator tubes (3). Secondary retaining clips (2 and 7) are installed over the connected couplers for added protection. The spring-lock refrigerant line couplers require special disconnect tools for disengaging the two coupler halves. The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected. Two O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. A secondary retaining clip (3) is installed over the connected coupler (5) for added protection. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1182 Hose/Line HVAC: Description and Operation Plumbing The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80 millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s). High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1183 Hose/Line HVAC: Description and Operation Line-A/C Discharge The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line for the 5.9L Diesel engine is serviced as an assembly with the suction line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use correct O-ring seal will cause the refrigerant system connection to leak. The A/C discharge line has no serviceable parts except the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is removed and installed. If the A/C discharge line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1184 Hose/Line HVAC: Description and Operation Line-A/C Liquid The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The liquid line for this model consist of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The liquid lines are made from light-weight aluminum, and use braze-less fittings. The front half of the liquid line includes the high-side service port and the rear half of the liquid line contains the fixed orifice tube. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is removed and installed. If the liquid line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 1185 Hose/Line HVAC: Description and Operation Line-A/C Suction The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line for the 5.9L Diesel engine is serviced as an assembly with the discharge line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The A/C suction line has no serviceable parts except for the rubber O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed and installed. If the A/C suction line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1186 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR AND R-134A CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134A SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. NOTE: - If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. - The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY . If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to Step 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to Step 1 of the System Low procedure. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Operate the heating-A/C system with the engine at idle under the following conditions for at least five minutes. - Doors or windows open - Transmission in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 3. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line Hose/Line HVAC: Service and Repair Coupler-Refrigerant Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1). 4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting. 6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4). INSTALLATION 1. Clean any dirt or foreign material from the springlock type refrigerant line coupler. 2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1189 CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak. 3. Install new O-rings (8) on the male half of the refrigerant line coupler. 4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Position the female half of the coupler over the male half of the coupler. 6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler. 7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler. 8. Install the secondary retaining clip (3) over connected coupler cage (5). 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1190 Hose/Line HVAC: Service and Repair Line-A/C Discharge REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the wire harness connector from the A/C pressure transducer (8). 4. Remove the nut (2) that secures the A/C discharge line (1) to the A/C condenser (3). 5. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring and dual plan seal. 6. Install plugs in, or tape over the discharge line fitting and condenser inlet port. 7. Remove the nut (7) that secures the A/C discharge line to the A/C compressor (6). 8. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring and dual plan seal. 9. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 10. Remove the A/C discharge line from the engine compartment. 11. If necessary, remove the A/C pressure transducer from the A/C discharge line. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1191 1. If removed, install the A/C pressure transducer (8) onto the A/C discharge line (1). 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the opened discharge line fitting and the inlet port on the A/C condenser (3). 4. Lubricate a new O-ring and dual plane seal with clean refrigerant oil and install them onto the discharge line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Install the A/C discharge line onto the A/C condenser. 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 20 N.m (15 ft. lbs.). 7. Remove the tape or plugs from the opened discharge line fitting and the outlet port on the A/C compressor (6). 8. Lubricate a new O-ring and dual plane seal with clean refrigerant oil and install them onto the discharge line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C discharge line onto the A/C compressor. 10. Install the nut (7) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.). 11. Connect the wire harness connector to the A/C pressure transducer. 12. Reconnect the negative battery cable. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1192 Hose/Line HVAC: Service and Repair Line-A/C Liquid WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing and mounting bracket. 5. Remove the plastic cover from the condenser outlet stud. 6. Remove the nut (8) that secures the front section of the A/C liquid line (10) to the A/C condenser (7). 7. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and dual plane seal. 8. Disengage the A/C liquid line from the body retaining clips (1 and 9). 9. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line (4). 10. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 11. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser outlet port. 12. Remove the front section of the A/C liquid line from the engine compartment. INSTALLATION NOTE: The A/C liquid line is serviced in two sections. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1193 1. Position the front section of the A/C liquid line (10) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser outlet port. 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (4). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. 6. Engage the A/C liquid line into the body retaining clips (1 and 9). 7. Lubricate a new O-ring and dual plane seal with clean refrigerant oil and install them onto the front liquid line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line to the outlet port of the A/C condenser (7). 9. Install the nut (8) that secures the A/C liquid line to the A/C condenser. Tighten the nut to 20 N.m (15 ft. lbs.). 10. Install the plastic cover onto the condenser outlet stud. 11. If equipped with a gasoline engine, install the air filter housing mounting bracket and air filter housing. 12. If equipped with the diesel engine, install the passenger side battery tray. 13. Reconnect the negative battery cable(s). 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. REAR SECTION REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1194 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing and mounting bracket. 5. Disengage the rear section of the A/C liquid line (4) from the body retaining clip (3). 6. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (10) to the rear section of the liquid line. 7. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the seal. 8. Remove the secondary retaining clip (5) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator inlet tube (6). 9. Using the proper A/C line disconnect tool, disconnect the A/C liquid line from the evaporator inlet tube and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator inlet port. 11. Remove the rear section of the A/C liquid line from the engine compartment. INSTALLATION 1. Position the rear section of the A/C liquid line (4) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator inlet tube (6). 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line spring-lock coupler fitting. Use only the specified seas as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1195 vehicle. 4. Connect the rear section of the A/C liquid line to the evaporator inlet tube. 5. Install the secondary retaining clip (5) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator inlet tube. 6. Engage the A/C liquid line into the body retaining clip (3). 7. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the rear section of the A/C liquid line to the front section of the liquid line (10). 9. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 10. If equipped with a gasoline engine, install the air filter housing mounting bracket and air filter housing. 11. If equipped with the diesel engine, install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1196 Hose/Line HVAC: Service and Repair Line-A/C Suction REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air filter housing. 4. Remove the nut (4) that secures the A/C suction line (5) to the A/C compressor (6). 5. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring and dual plane seal. 6. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 7. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 8. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 9. Install plugs in, or tape over the opened suction line fitting and the accumulator outlet tube. 10. Remove the A/C suction line from the engine compartment. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 1197 1. Position the A/C suction line (5) into the engine compartment. 2. Remove the tape or plugs from the opened fitting on the A/C suction line and the inlet port on the A/C compressor (6). 3. Lubricate a new O-ring and dual plan seal with clean refrigerant oil and install them onto the suction line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the A/C suction line onto the A/C compressor. 5. Install the nut (4) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.). 6. Remove the tape or plugs from the opened suction line fitting and the accumulator outlet tube. 7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the A/C suction line (6) to the spring-lock coupler (1) on the accumulator (5) and install the secondary retaining clip (7) 9. Install the air filter housing cover. 10. Reconnect the negative battery cable. 11. Evacuate the refrigerant system. 12. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Return Hose-Gear to Cooler Power Steering Line/Hose: Service and Repair Return Hose-Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 Nm (37 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Return Hose-Gear to Cooler > Page 1202 Power Steering Line/Hose: Service and Repair Pressure Hose PRESSURE HOSE REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Return Hose-Gear to Cooler > Page 1203 Power Steering Line/Hose: Service and Repair Return Hose - Reservoir to Cooler RETURN HOSE-RESERVOIR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1209 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1210 Brake Fluid: Specifications Hydraulic Brake Fluid Type ............................................................................................................................................... Mopar DOT 3 and SAE J1703 Note: If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1211 Brake Fluid: Description and Operation BRAKE FLUID DESCRIPTION The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1212 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1213 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1218 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Page 1219 Clutch Fluid: Specifications Chrysler does not provide a fluid type for the hydraulic clutch system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1224 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ....................................................... 18.7 qts. (17.7 L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1227 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1228 Coolant: Description and Operation ENGINE COOLANT DESCRIPTION WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5°C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1229 properly mixed coolant solution. CAUTION: Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1230 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F). to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1235 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1240 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1245 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1250 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1255 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1256 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1257 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1258 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1259 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1260 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1261 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 42RLE Service Fill ............................................................................................................................... ................................................................ 4 Qt (3.8L) 42RLE Overhaul Fill ......................................... ............................................................................................................................................. 17.6 pts (8.3L) 45RFE/545RFE 2WD Service Fill ............................................................................................. ....................................................................... 11 pts (5.2L) 45RFE/545RFE 4WD Service Fill .......... .......................................................................................................................................................... 13 pts (6.2L) 45RFE/545RFE Overhaul Fill ......................................................................................... ........................................................................ 29-33 pts (14-16L) 48RE Service Fill ......................... .............................................................................................................................................................. .......... 4 Qt (3.8L) 48RE Overhaul Fill ................................................................................................. ................................................................................. 29-33 pts (14-16L) Overhaul Fill - Dry Fill Capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1264 Fluid - A/T: Fluid Type Specifications ATF Type ............................................................................................................................................. .......................................................... Mopar ATF+4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed Fluid - A/T: Service and Repair 45RFE 4 Speed/545RFE 5 Speed Fluid Level and Condition Check FLUID AND FILTER DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. FLUID CONTAMINATION Transmission fluid contamination is generally a result of: ^ adding incorrect fluid ^ failure to clean dipstick and fill tube when checking level ^ engine coolant entering the fluid ^ internal failure that generates debris ^ overheat that generates sludge (fluid breakdown) ^ failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 1267 The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F), the fluid level is correct if it is in the HOT region (crosshatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21°C (70°F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid and Filter Service FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 1268 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to testing. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (7 ft. lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR ATF +4. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4 to transmission: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 1269 a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 1270 Fluid - A/T: Service and Repair 42RLE Automatic Transmission Fluid Level Check - 42RLE FLUID AND FILTER CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. FLUID CONTAMINATION Transmission fluid contamination is generally a result of: ^ adding incorrect fluid ^ failure to clean dipstick and fill tube when checking level ^ engine coolant entering the fluid ^ internal failure that generates debris ^ overheat that generates sludge (fluid breakdown) ^ failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. FLUID LEVEL CHECK The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the PARK and NEUTRAL positions. Place the selector lever in PARK to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature ( approximately 82° C or 180°F), the fluid level is correct if it is in the HOT region (crosshatched area) on the oil level indicator. The fluid level should be in COLD region at 21°C (70°F) fluid temperature. Adjust fluid level as necessary Use only Mopar ATF+4, Automatic Transmission Fluid. FLUID LEVEL CHECK USING SCAN TOOL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 1271 NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Connect scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. 5. Compare the fluid temperature value with the chart. 6. Adjust transmission fluid level shown on the dipstick according to the 42RLE Fluid Temperature Chart. Use only Mopar ATF+4, Automatic Transmission Fluid. 7. Check transmission for leaks. Fluid/Filter Service - 42RLE FLUID/FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF+4, Automatic Transmission Fluid, should be used in the transmission sump. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transmission is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transmission oil pan. NOTE: One of the oil pan bolts (5) has a sealing patch applied from the factory. Separate this bolt for reuse. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 1272 3. Install a new filter and o-ring on bottom of the valve body and tighten retaining screws to 5 Nm (45 inch lbs.). NOTE: Before installing the oil pan bolt (5) in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits, it will be necessary to replenish the sealing patch on the bolt using Mopar Lock & Seal Adhesive. 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 20 Nm (14.5 ft. lbs.). 5. Pour four quarts of Mopar ATF+4, Automatic Transmission Fluid, through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick. 8. Recheck the fluid level after the transmission has reached normal operating temperature, 82°C (180°F). 9. To prevent dirt from entering transmission, make certain that dipstick is fully seated into the dipstick opening. Transmission Fill - 42RLE TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (11/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and recheck. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1277 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1282 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications 5.7L G56 .............................................................................................................................................. ............................................................. 10 pts (4.7L) GETRAG 238 ...................................................................................................................................... ............................................................. 4.6 pts (2.2L) TREMEC T-56 ..................................................................................................................................... .......................................................... 4.8 pts (2.27L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1285 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type ......................................................................................................... .......................................................... Mopar ATF+4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1290 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1291 Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1292 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Axle Fluid ............................................................................................................................................. ........................................................ +\- 1 oz (0.03L) 9 1/4 .................................................................. ........................................................................................................................................... 72 oz (2.1L) *** 10 1/2 AA ............................................................................................................................. ................................................................................ 85 oz. 2.5L 10 1/2 AA EL .................................... .............................................................................................................................................................. ... 85 oz (2.5L) 11 1/2 AA Open ........................................................................................................... .................................................................................... 142 oz (4.2L) 11 1/2 AA Trac-Rite .................. .............................................................................................................................................................. ......... 135 oz (4.0L) 248RBI (Dana 60) ............................................................................................... ....................................................................................... 46 oz (2.8L)**** *** ............................................................................................................................................. With Trac-Lok add 4 oz (118 ml) of Limited Slip Additive **** ..................................................................... .............................................................................................. Add 5 oz (147 ml) of Limited Slip Additive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1295 Fluid - Differential: Fluid Type Specifications 9 1/4 ..................................................................................................................................................... ............... Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL ....................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA Open .................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 248RBI (Dana 60) .................................................................................................................................................... Mopar Gear & Axle Lubricant SAE 90 Note: Trac-Lok Differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1300 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1305 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ..................................................... 6.6Liters (7.0 Qt) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1308 Engine Oil: Fluid Type Specifications An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. For 5.7L engines SAE 5W-20 engine oil is recommended for all operating temperatures. These engine oils improve low temperature starting and vehicle fuel economy. Refer to your engine oil filler cap for the recommended engine oil viscosity for your vehicle. Vehicles with 5.7L engines equipped with Multiple Displacement System (MDS) must use SAE 5W-20 oil. Failure to do so may result in improper operation of the Multiple Displacement System (MDS). Refer to the engine oil filler cap for the recommended engine oil viscosity for each vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1309 Engine Oil: Testing and Inspection ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1310 Engine Oil: Service and Repair ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to Service Precautions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1315 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1316 Power Steering Fluid: Specifications Power Steering Fluid Type .................................................................................................................. .......................................................... Mopar ATF+4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1317 Power Steering Fluid: Description and Operation FLUID DESCRIPTION NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar ATF +4. Mopar ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Flushing Power Steering System Power Steering Fluid: Service and Repair Flushing Power Steering System FLUSHING POWER STEERING SYSTEM Flushing is required when the power steering/hydraulic booster system fluid has become contaminated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steering gear/booster spool valve operation. NOTE: The engine should not be run so that all of the fluid is drained from the system. The pump should never be run without fluid. 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the return line from the pump. NOTE: If vehicle is equipped with a hydraulic booster remove both return lines from the pump. 3. Plug the return line port/ports at the pump. 4. Position the return line/lines into a large container to catch the fluid. 5. While an assistant is filling the pump reservoir start the engine. 6. With the engine running at idle turn the wheel back and forth. NOTE: Do not contact or hold the wheel against the steering stops. 7. Run a quart of fluid through the system then stop the engine and install the return line/lines. 8. Fill the system with fluid and perform Steering Pump Initial Operation. 9. Start the engine and run it for fifteen minutes then stop the engine. 10. Remove the return line/lines from the pump and plug the pump port/ports. 11. Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again. 12. Install the return line/lines and perform Steering Pump Initial Operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Service and Repair > Flushing Power Steering System > Page 1320 Power Steering Fluid: Service and Repair Power Steering Fluid Level Checking POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar ATF+4. Do not overfill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-134a Refrigerent Charge Capacity 1. 3.7/4.7/5.7/8.3 L ............................................................................................................................... ........................................... 0.728 kg (1.604 lbs.) 2. 5.9 L ................................................................... ....................................................................................................................... 0.850 kg (1.873 lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1325 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1326 Refrigerant: Description and Operation The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1327 Refrigerant: Service and Repair WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Always refer to the Underhood HVAC Specification Label for the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the Underhood HVAC Specification Label. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle ( about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH PRESSURE) VALVE AT THIS TIME. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1332 Refrigerant Oil: Fluid Type Specifications Denso 10S17 A/C Compressor ........................................................................................................... ........................................................... ND-8 PAG Oil Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1333 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the A/C Underhood Specification Label located in the engine compartment). The Denso 10S17 A/C compressor used in this vehicle when equipped with the 3.7L, 4.7L, 5.7L or 8.3L engine is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for these engines. The Visteon HS-18 A/C compressor used in this vehicle when equipped with 5.9L diesel engine is designed to use VC-46 PAG refrigerant oil. Use only this type of refrigerant oil when servicing this A/C compressor. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1334 Refrigerant Oil: Service and Repair When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when an accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. When an A/C compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1339 Brake Bleeding: Service and Repair Base Brake System MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1340 Brake Bleeding: Service and Repair Antilock Brake System ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1341 Brake Bleeding: Service and Repair Hydraulic Brake Booster BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 1346 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 1347 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 1357 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 1363 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1364 Fuse: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1365 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1366 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1367 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1368 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1391 Fuse: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1392 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1393 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1394 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Page 1395 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1399 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1400 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1401 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Page 1402 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1405 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1406 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1407 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1408 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1409 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1410 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1411 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1412 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1413 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1414 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1415 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1416 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1417 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1418 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1419 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1420 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1421 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1422 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1423 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1424 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1425 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1426 Fuse Block: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1427 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1428 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1429 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Page 1430 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1434 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1435 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1436 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1437 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1438 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1439 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1440 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1441 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1442 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1443 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position, the SKREEM sends a TPM lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Lamp-On Message - Each time the cluster receives a TPM lamp-on message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a TPM lamp-off message from the SKREEM or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid TPM lamp-on or lamp-off message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the On position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper TPM lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is inoperative. For proper diagnosis of the SKREEM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the TPM indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Chrysler provides no information regarding a Maintenance Required Lamp/Indicator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC s, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC s may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Chrysler provides no information regarding a Oil Change Reminder Lamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Standard Procedure Refer to the Owner's Manual for emergency vehicle lifting procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1461 WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACK Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1462 When properly positioned, a floor jack can be used to lift a vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not lift vehicle with a floor jack positioned under: An axle tube. A body side sill. A steering linkage component. A drive shaft. The engine or transmission oil pan. The fuel tank. A front suspension arm. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1463 NOTE: Use the correct front frame rail lifting locations only. NOTE: Use the correct rear frame rail lifting locations only. HOIST Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1464 A vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1465 NOTE: The forward lifting pads should be positioned against the forward flange of the transmission crossmember brackets at the bottom of the frame rail. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 1466 NOTE: The rear lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail. Safety stands should be placed under the frame rails at the front and rear ends. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position, the SKREEM sends a TPM lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Lamp-On Message - Each time the cluster receives a TPM lamp-on message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a TPM lamp-off message from the SKREEM or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid TPM lamp-on or lamp-off message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the On position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper TPM lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is inoperative. For proper diagnosis of the SKREEM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the TPM indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 1479 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1480 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1481 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, The rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1482 wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 1483 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1496 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1497 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1498 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1499 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1500 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1501 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1502 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1512 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1513 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1514 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1515 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1516 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1517 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1518 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 1519 Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal Wheel Bearing: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal > Page 1522 Wheel Bearing: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair WHEEL COVER REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with Dual Rear Wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. 4. The wheel skins can now be removed from the wheel. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. INSTALLATION REAR 1. Install one 1 1/2 inch valve stem extension on each rear inner wheel. NOTE: A 3/8 inch drive 10mm deep wheel socket with a 10 inch or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 inch valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike the wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1538 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1539 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1540 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1541 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1542 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1543 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1544 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: All Technical Service Bulletins Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 1550 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1564 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1565 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1566 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1567 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1568 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1569 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 23-010-07 > Mar > 07 > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1570 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1580 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1581 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1582 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1583 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1584 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1585 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1586 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: Customer Interest Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 1595 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: All Technical Service Bulletins Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 1601 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations Headliner Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1604 Console: Service and Repair FLOOR CONSOLE REMOVAL Mini Floor Console 1. If equipped, remove the 4WD gear shift boot. 2. If equipped with a manual transmission, remove the transmission gear shift lever extension. 3. Remove the console inserts, if equipped. 4. Remove the bolts (2) that secure the rear console (1) to the floor panel. 5. Lift up the rear of the floor console to clear the gear shift lever, if equipped. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1605 6. Remove the bolts (2) and separate the front console (3) from the floor. 7. Separate the front clips (1) and remove the mini console. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. 2. Using a trim stick C-4755 or equivalent, separate the seven front console bezel clips (2), lift up the back of the bezel (1) and remove. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1606 3. Remove the bolts (1) and lift the rear of the base up to release the front guide pins (5). 4. Remove the front base (2). NOTE: Do not reuse the seat fasteners, always replace with new ones. 5. Remove and discard the front bolts (4). 6. Position the seats forward, remove the rear bolts (2) and discard. 7. Disconnect the 12 v power supply electrical connector (3-if equipped). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1607 8. Fold the seat backs forward and roll the seat assembly (1) back in the vehicle. 9. Remove the nuts (2) attaching the center seat console (1) to the drivers seat and the passenger seat and discard. 10. Remove the nuts (4) attaching the center console (2) to the drivers seat (3) and the passenger seat in the rear of the seat and discard. 11. Disconnect the electrical connector (1-if equipped). 12. Roll the seat assembly forward and remove the center seat console. INSTALLATION Mini Floor Console Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1608 1. Position the console and seat the front clips (1) fully. 2. Install the bolts (2). 3. Install the bolts (2) that secure the rear console (1) to the floor panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1609 4. Install the inserts. 5. Install the gear shift lever extension. 6. Install the 4WD gear shift boot. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Position the center seat console onto the front seat assembly and roll the seat assembly back in the vehicle. 3. Install new nuts (4) attaching the center console to the drivers (3) and passenger seat. 4. Connect the electrical connector (1-if equipped). 5. Tighten the nuts (4) to 25 N.m (18 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Component Information > Locations > Page 1610 6. Install new nuts (2) attaching the center console (1) to the drivers and passenger seat. 7. Tighten the nuts to 25 N.m (18 ft.lbs.). 8. Connect the electrical connector (3 and 5-if equipped). 9. Roll the seat assembly forward and install new rear bolts (2). 10. Connect the 12 v power supply electrical connector (3-if equipped). 11. Tighten the rear bolts to 40 N.m (30 ft.lbs.). 12. Fold the seat backs up and slide the seats to the rear. 13. Install new front bolts (4) and tighten to 28 N.m (21 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1619 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1620 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1621 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1622 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1623 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1624 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1625 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1631 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1632 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1633 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1634 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1635 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1636 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 1637 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS 1500 Series Lug Nut 9/16 X 18 with 60° Cone LD .............................................................................................................................. 183 Nm (135 ft. lbs.) 2500 Series Lug Nut 9/16 X 18 with 60° Cone HD SRW .................................................................................................................... 197 Nm (145 ft. lbs.) 3500 Series Lug Nut 9/16 X 18 with Flat Washer HD DRW ............................................................................................................... 210 Nm (155 ft. lbs.) 8-lug. (SRT-10). 6-bolt pattern. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1641 Wheel Fastener: Service and Repair STUDS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using special tool C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 1642 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Standard Procedure Refer to the Owner's Manual for emergency vehicle lifting procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1646 WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACK Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1647 When properly positioned, a floor jack can be used to lift a vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not lift vehicle with a floor jack positioned under: An axle tube. A body side sill. A steering linkage component. A drive shaft. The engine or transmission oil pan. The fuel tank. A front suspension arm. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1648 NOTE: Use the correct front frame rail lifting locations only. NOTE: Use the correct rear frame rail lifting locations only. HOIST Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1649 A vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1650 NOTE: The forward lifting pads should be positioned against the forward flange of the transmission crossmember brackets at the bottom of the frame rail. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair > Page 1651 NOTE: The rear lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail. Safety stands should be placed under the frame rails at the front and rear ends. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams Valve Deactivation Solenoid: Diagrams Solenoid - Multiple Displacement No.1 (5.7L) Solenoid - Multiple Displacement No.4 (5.7L) Solenoid - Multiple Displacement No.6 (5.7L) Solenoid - Multiple Displacement No.7 (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Page 1658 Valve Deactivation Solenoid: Description and Operation SOLENOID-MDS DESCRIPTION The Multi Displacement System selectively deactivates cylinders 1,4,6, and 7, to improve fuel economy. It has two modes of operation: 8 cylinders for acceleration and heavy loads. - 4 cylinders for cruising and city traffic. The main components of the Multi Displacement System are Unique MDS camshaft. - Deactivating roller tappets. - 4 control valves/solenoids. - control valve/solenoid wiring harness. - oil temp sensor. OPERATION Cylinder Deactivation - Trap an exhaust charge from a normal combustion event - Normal combustion event - Don't open the exhaust valve - Don't open the intake valve - Piston is an air spring - Cylinders deactivated in firing sequence Cylinder Reactivation - Open the exhaust valve - Empty the cylinder - Open the intake valve - Normal combustion event - Cylinders reactivated in firing sequence Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Page 1659 Valve Deactivation Solenoid: Testing and Inspection SOLENOID-MDS The Multi Displacement System has the following detectable issues: Solenoid circuit - Fail to deactivate a cylinder(s) - Fail to reactivate a cylinder(s) - Low oil pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Page 1660 Valve Deactivation Solenoid: Service and Repair SOLENOID-MDS REMOVAL 1. Disconnect the negative battery cable. 2. Remove the intake manifold. 3. Remove wiring harness connectors from the MDS solenoids. 4. Remove hold down bolt from MDS solenoid. 5. Remove MDS solenoid. INSTALLATION 1. Verify that MDS bores are free of debris, before solenoid installation. 2. Install MDS solenoid fully into block. 3. Install hold down bolt and torque to 11 Nm (97 inch lbs.). 4. Reconnect the MDS wiring harness to the solenoids. 5. Install the intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 1664 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair Camshaft: Service and Repair CAMSHAFT REMOVAL - CAMSHAFT CORE HOLE PLUG CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug. 1. Remove the rear cam bearing core plug. REMOVAL - CAMSHAFT 1. Remove the battery negative cable. 2. Remove the air cleaner assembly. 3. Drain coolant. 4. Remove the accessory drive belt. 5. Remove the generator. 6. Remove the A/C compressor, and set aside. 7. Remove the radiator. 8. Remove intake manifold. 9. Remove cylinder head covers. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1669 10. Remove both left and right cylinder heads (4). 11. Remove the oil pan. 12. Remove timing case cover (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1670 13. Remove the oil pick up tube. 14. Remove the oil pump. 15. Remove timing chain (2). 16. Remove camshaft tensioner/thrust plate assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1671 NOTE: Identify lifters; to ensure installation in original location. 17. Remove the tappets (2) and retainer (1) assembly. 18. Install a long bolt into front of camshaft to aid in removal of the camshaft. Remove camshaft, being careful not to damage cam bearings with the cam lobes. INSPECTION 1. The cam bearings are not serviceable. Do not attempt to replace cam bearings for any reason. INSTALLATION - CAMSHAFT CORE HOLE PLUG 1. Clean core hole in block. NOTE: Do not apply adhesive to the new core hole plug. A new plug will have adhesive pre-applied. 2. Install a new core hole plug at the rear of camshaft, using suitable flat faced tool. The plug must be fully seated on the cylinder block shoulder. INSTALLATION - CAMSHAFT CAUTION: 5.7L engines equipped with MDS uses a unique camshaft for use with the Multi Displacement System. When installing a new camshaft, the replacement camshaft must be compatible with the Multi Displacement System. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1672 1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft (figure 1). 2. Install camshaft Tensioner plate assembly. Tighten bolts to 28 Nm (250 inch lbs.) torque. 3. Install timing chain and sprockets. 4. Measure camshaft end play. If not within limits install a new thrust plate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1673 5. Install the oil pump (figure2). 6. Install the oil pick up tube. 7. Each tappet (2) reused must be installed in the same position from which it was removed. When camshaft is replaced, all of the tappets must be replaced. CAUTION: 5.7L engines equipped with MDS uses both standard roller tappets and deactivating roller tappets, for use with the Multi Displacement System. The deactivating roller tappets must be used in cylinders 1,4,6,7. The deactivating tappets can be identified by the two holes in the side of the tappet body, for the latching pins. 8. Install tappets (2) and retaining yoke assembly (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1674 9. Install both left and right cylinder heads (4). 10. Install pushrods. 11. Install rocker arms. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1675 12. Install timing case cover (figure4). 13. Install the oil pan. 14. Install cylinder head covers. 15. Install intake manifold. 16. Install the A/C compressor (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Page 1676 17. Install the generator (2). 18. Install the accessory drive belt.. 19. Install the radiator. 20. Install the air cleaner assembly. 21. Install the battery negative cable. 22. Refill coolant. 23. Refill engine oil. 24. Start engine and check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection Lifter / Lash Adjuster: Testing and Inspection HYDRAULIC TAPPETS Before disassembling any part of the engine to correct tappet noise, check the oil pressure. if vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-70 psi) at 3,000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these two conditions could be responsible for noisy tappets. OIL LEVEL HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. LOW Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out. TAPPET NOISE DIAGNOSIS 1. To determine source of tappet noise, crank over engine with cylinder head covers removed. 2. Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. 3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leakdown around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. 4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it's probably not the tappets. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1680 Lifter / Lash Adjuster: Service and Repair TAPPETS - HYDRAULIC ROLLER REMOVAL 1. Disconnect the negative cable from the battery. 2. Remove the air cleaner. 3. Remove intake manifold. 4. Remove cylinder head cover. 5. Remove rocker arm assembly and push rods. Identify push rods to ensure installation in original location. 6. Remove the cylinder head. 7. Remove bolt from tappet retainer (1). 8. Remove tappet retainer (1). 9. Pull tappet out of bore with a twisting motion. If all tappets are to be removed and reused, identify tappets to ensure installation in original location. 10. Check camshaft lobes for abnormal wear. INSTALLATION 1. Lubricate tappets. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Testing and Inspection > Page 1681 CAUTION: 5.7L engines equipped with MDS uses both standard roller tappets and deactivating roller tappets, for use with the Multi Displacement System. The deactivating roller tappets must be used in cylinders 1,4,6,7. The deactivating tappets can be identified by the two holes in the side of the tappet body, for the latching pins. 2. Install tappets in their original positions. 3. Install tappet retainer (1). Install the tappet retainer bolt and tighten to 12 Nm (106 inch lbs.) torque. 4. Install cylinder head. 5. Install pushrods and rocker arm assembly. 6. Install cylinder head cover. 7. Install intake manifold. 8. Install the air cleaner. 9. Connect the negative cable to the battery. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet. 10. Road test vehicle and check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair ROCKER ARM REMOVAL 1. Remove cylinder head cover. 2. Install pushrod retaining plate (1) special tool 9070. 3. Loosen the rocker shafts using the sequence provided. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1685 CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an "I". 4. Remove the rocker shafts. Note location for reassembly. CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. 5. Remove the pushrods. Note pushrod location for reassembly. CAUTION: Do not remove the retainers from the rocker shaft. The assembly tangs (1) at the bottom of the retainers (2) can be damaged, causing the assembly tangs to break off, and get into the engine. INSTALLATION CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. 1. Install the push rods in the same order as removed. 2. Install the pushrod retaining plate (1) special tool 9070. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1686 CAUTION: Ensure that retainers (2) and rocker arms (4) are not overlapped when torquing bolts. CAUTION: Verify that pushrod is installed into rocker arm (4) and tappet correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter "I". 3. Install rocker shaft assemblies in the same order as removed. 4. Tighten the rocker shaft bolts to 22 Nm (195 inch lbs.) torque, using the sequence provided. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 1687 5. Remove pushrod retaining plate (1) special tool 9070. 6. Install cylinder head cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications CONNECTING RODS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING RODS Connecting Rod Cap-Bolts ................................................................................................................................................. 21 Nm (15 ft. lbs.) plus 90° Turn Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1695 Connecting Rod: Description and Operation PISTON & CONNECTING ROD DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a fractured cap design. A pressed fit piston pin is used to attach the piston and connecting rod. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1696 Connecting Rod: Service and Repair PISTON & CONNECTING ROD REMOVAL 1. Disconnect negative cable from battery. 2. Remove the following components: ^ Oil pan and gasket/windage tray. ^ Cylinder head covers and. ^ Timing chain cover. ^ Cylinder head(s) and. 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. 4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1697 6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces. 7. Carefully remove piston rings from piston(s), starting from the top ring down. CLEANING CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly. INSPECTION Check the connecting rod journal for excessive wear, taper and scoring. Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. INSTALLATION 1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil. 4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads. 5. The pistons are marked on the piston pin bore surface with an raised F or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. 6. Wipe cylinder bore clean and lubricate with engine oil. 7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1698 CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. 9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 Nm (15 ft. lbs.) plus a 90° turn. 10. Install the following components: ^ Cylinder head(s).. ^ Cylinder head covers. ^ Install the intake manifold. ^ Oil pan and gasket/windage tray. 11. Fill crankcase with proper engine oil to correct level. 12. Connect negative cable to battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main Bearing Cap-Bolts M-12 .............................................................................................................................................................. 27 Nm plus 90° Turn CRANKSHAFT Service Specifications MAIN BEARING SELECTION CHART - 5.7L Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Page 1702 Crankshaft Main Bearing: Service and Repair CRANKSHAFT MAIN BEARING - FITTING MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) Crankshaft removed from the cylinder block. Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal. The maximum allowable taper is 0.008 mm (0.0004 inch) and maximum out of round is 0.005 mm (0.0002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. CRANKSHAFT MAIN BEARING SELECTION The main bearings are select fit to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right, corresponding with journal number 1, 2, 3, 4 and 5. NOTE: Service main bearings are coded. These codes identify what size (grade) the bearing is. MAIN BEARING SELECTION CHART - 5.7L INSPECTION Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated. NOTE: If any of the crankshaft journals are scored, the crankshaft must be repaired or replaced. Inspect the back of the inserts for fractures, scrapings or irregular wear patterns. Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair Crankshaft Seal Retainer: Service and Repair RETAINER - CRANK REAR OIL - SEAL REMOVAL 1. Disconnect negative cable from battery. 2. Remove the transmission. 3. Remove the flexplate.. 4. Remove the oil pan. 5. Remove the rear oil seal retainer mounting bolts. 6. Carefully remove the retainer from the engine block. INSTALLATION 1. Thoroughly clean all gasket residue from the engine block. 2. Use extreme care and clean all gasket residue from the retainer. 3. Position the gasket onto the retainer. 4. Position the retainer onto the engine block. 5. Install the retainer mounting bolts. Tighten the bolts to 15 Nm (132 inch lbs.) using the procedure shown. 6. Install the oil pan. 7. Install the flexplate 8. Install the transmission. 9. Check and verify engine oil level. 10. Start engine and check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications CRANKSHAFT Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1709 Crankshaft: Service and Repair CRANKSHAFT REMOVAL 1. Remove the vibration damper (1). 2. Remove the rear oil seal retainer. 3. Remove the oil pan. 4. Remove the oil pump pickup. 5. Remove the windage tray/oil pan gasket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1710 6. Remove the timing chain cover. 7. Remove the oil pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1711 8. Remove the timing drive (2). 9. Identify rod bearing caps before removal. Remove rod bearing caps with bearings. 10. Identify main bearing caps (1) before removal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1712 11. Remove main bearing caps (1) and bearings one at a time. 12. Remove the thrust washers. 13. Remove the crankshaft out of the block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1713 1. Select the proper main bearings. 2. Install main bearings in block and caps, and lubricate bearings. 3. Position the crankshaft into the cylinder block. 4. Install the thrust washers (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1714 NOTE: The main cap crossbolts are torqued after final torque of the main cap bolts. Always use a new washer/seal on crossbolts. 5. Clean and oil all cap bolts. Install all main bearing caps (1). Install all cap bolts and alternately tighten in two steps using the following sequence. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1715 6. ^ Step 1 - 27 Nm (20 ft. lbs.) torque. 7. ^ Step 2 - Turn main cap bolts an additional 90°. 8. Install the crossbolts with new washer/gasket. Starting with crossbolt A torque each crossbolt to 28 Nm ( 21 ft. lbs.) torque. 9. Repeat crossbolt torque procedure. 10. Measure crankshaft end play. 11. Position the connecting rods onto the crankshaft and install the rod bearing caps. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1716 12. Install timing drive (2). 13. Install oil pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 1717 14. Install the timing chain cover (1). 15. Install the rear main seal and retainer. 16. Install the windage tray/oil pan gasket. 17. Install the oil pick up tube. 18. Install the oil pan. 19. Install the vibration damper. 20. Install the engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation HEATER-ENGINE BLOCK DESCRIPTION WARNING: DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE. THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS. An optional engine block heater is available with all models. The heater is equipped with a power cord. The cord is attached to an engine compartment component with tie-straps. The heater warms the engine providing easier engine starting and faster warm-up in low temperatures. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant. The 3.7L/4.7L gas powered engines have the block heater located to the rear on the right side of the engine. The 5.9L diesel engine has the block heater located on the right side of the engine below the exhaust manifold next to the oil cooler (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1721 The 5.7L engine has the block heater (1) located on the left side of the engine below the exhaust manifold in the rear of the engine and is not immersed in engine coolant but makes direct contact with the block. OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1722 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or 110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in it's retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 1723 Engine Block Heater: Service and Repair HEATER-ENGINE BLOCK REMOVAL 5.7L 1. Raise vehicle. 2. Remove power cord from block heater. 3. Remove bolt on block heater. Remove heater assembly. INSTALLATION 1. Thoroughly clean cylinder block core hole and block heater seat. 2. Insert block heater assembly into the block. 3. With block heater fully seated, tighten bolt to 2 Nm (17 inch lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Vibration Damper-Bolt ......................................................................................................................... ................................................. 176 Nm (129 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1727 Harmonic Balancer - Crankshaft Pulley: Service and Repair DAMPER - CRANKSHAFT REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Drain cooling system. 4. Remove radiator upper hose. 5. Remove fan shroud. 6. Remove crankshaft damper bolt. 7. Remove damper using Special Tools 8513A Insert and 1023 Three Jaw Puller. INSTALLATION CAUTION: To prevent severe damage to the Crankshaft, Damper or Special Tool 8512-A, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 1. Slide damper onto crankshaft slightly CAUTION: Special Tool 8512-A, is assembled in a specific sequence. Failure to assemble this tool in this sequence can result in tool failure and severe damage to either the tool or the crankshaft. 2. Assemble Special Tool 8512-A as follows, The nut is threaded onto the shaft first (2). Then the roller bearing (1) is placed onto the threaded rod (3) The hardened bearing surface of the bearing (1) MUST face the nut (2). Then the hardened washer (5) slides onto the threaded rod (3). Once assembled coat the threaded rod's threads with Mopar Nickel Anti-Seize or (Loctite No. 771). 3. Using Special Tool 8512-A, press damper onto crankshaft. 4. Install then tighten crankshaft damper bolt to 176 Nm (129 ft. lbs.). 5. Install radiator upper hose. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1728 6. Install accessory drive belt. 7. Refill cooling system. 8. Connect negative cable to battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications PISTON PINS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 1732 Piston: Description and Operation PISTON & CONNECTING ROD DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy Piston skirts are coated with a solid lubricant (Molykote) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a fractured cap design. A pressed fit piston pin is used to attach the piston and connecting rod. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures PISTON FITTING 1. To correctly select the proper size piston, a cylinder bore gauge, capable of reading in 0.003 mm (.0001 inch) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. 2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B. 3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank ( odd numbered) and the right cylinder bank ( even numbered) and must not be interchanged. 4. The coating material is applied to the piston after the final piston machining process. Measuring the outside diameter of a coated piston will not provide accurate results. Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY. To correctly select the proper size piston, a cylinder bore gauge capable of reading in 0.003 mm (0.0001 inch) increments is required. 5. Piston installation into the cylinder bore requires slightly more pressure than that required for noncoated pistons. The bonded coating on the piston will give the appearance of a line-to-line fit with the cylinder bore. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1735 Piston: Removal and Replacement PISTON & CONNECTING ROD REMOVAL 1. Disconnect negative cable from battery. 2. Remove the following components: ^ Oil pan and gasket/windage tray. ^ Cylinder head covers and. ^ Timing chain cover. ^ Cylinder head(s) and. 3. If necessary, remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so the each connecting rod is centered in cylinder bore. CAUTION: DO NOT use a number stamp or a punch to mark connecting rods or caps, as damage to connecting rods could occur NOTE: Connecting rods and bearing caps are not interchangeable and should be marked before removing to ensure correct reassembly. 4. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. 5. Remove connecting rod cap. Install Special Tool 8507 Connecting Rod Guides into the connecting rod being removed. Remove piston from cylinder bore. Repeat this procedure for each piston being removed. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1736 6. Immediately after piston and connecting rod removal, install bearing cap on the mating connecting rod to prevent damage to the fractured cap and rod surfaces. 7. Carefully remove piston rings from piston(s), starting from the top ring down. CLEANING CAUTION: DO NOT use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a Moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: DO NOT remove the piston pin from the piston and connecting rod assembly. INSPECTION Check the connecting rod journal for excessive wear, taper and scoring. Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. INSTALLATION 1. Before installing piston and connecting rod assemblies into the bore, install the piston rings. 2. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten ring compressor. Ensure position of rings do not change during this operation. 3. Position bearing onto connecting rod. Lubricate bearing surface with clean engine oil. 4. Install Special Tool 8507 Connecting Rod Guides into connecting rod bolt threads. 5. The pistons are marked on the piston pin bore surface with an raised F or arrow on top of piston indicating installation position. This mark must be pointing toward the front of engine on both cylinder banks. 6. Wipe cylinder bore clean and lubricate with engine oil. 7. Rotate crankshaft until connecting rod journal is on the center of cylinder bore. Insert rod and piston into cylinder bore and carefully position connecting rod guides over crankshaft journal. 8. Tap piston down in cylinder bore using a hammer handle. While at the same time, guide connecting rod into position on rod journal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 1737 CAUTION: Connecting Rod Bolts are Torque to Yield Bolts and Must Not Be Reused. Always replace the Rod Bolts whenever they are loosened or removed. 9. Lubricate rod bolts and bearing surfaces with engine oil. Install connecting rod cap and bearing. Tighten bolts to 21 Nm (15 ft. lbs.) plus a 90° turn. 10. Install the following components: ^ Cylinder head(s).. ^ Cylinder head covers. ^ Install the intake manifold. ^ Oil pan and gasket/windage tray. 11. Fill crankcase with proper engine oil to correct level. 12. Connect negative cable to battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RINGS PISTON RINGS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1741 Piston Ring: Service and Repair PISTON RING FITTING Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Wipe the cylinder bore clean. 2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch) from bottom of cylinder bore. 3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder. 4. Using a feeler gauge check the ring end gap. Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 5. Measure the ring side clearance as shown make sure the feeler gauge fits snugly between the ring land and the ring. Replace any ring not within specification. 6. Rotate the ring around the piston, the ring must rotate in the groove with out binding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1742 PISTON RING SPECIFICATION CHART PISTON RING SPECIFICATION CHART 7. The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: ^ Oil ring expander. ^ Lower oil ring side rail. ^ Upper oil ring side rail. ^ No. 2 Intermediate piston ring. ^ No. 1 Upper piston ring. 8. Install the oil ring expander. 9. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 1743 10. Install No. 2 intermediate piston ring using a piston ring installer. 11. Install No. 1 upper piston ring using a piston ring installer. 12. Position piston ring end gaps as shown in. It is important that expander ring gap is at least 45° from the side rail gaps, but not on the piston pin center or on the thrust direction. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair ROCKER ARM REMOVAL 1. Remove cylinder head cover. 2. Install pushrod retaining plate (1) special tool 9070. 3. Loosen the rocker shafts using the sequence provided. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1751 CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with an "I". 4. Remove the rocker shafts. Note location for reassembly. CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. 5. Remove the pushrods. Note pushrod location for reassembly. CAUTION: Do not remove the retainers from the rocker shaft. The assembly tangs (1) at the bottom of the retainers (2) can be damaged, causing the assembly tangs to break off, and get into the engine. INSTALLATION CAUTION: The longer push rods are for the exhaust side, and the shorter push rods are for intake side. 1. Install the push rods in the same order as removed. 2. Install the pushrod retaining plate (1) special tool 9070. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1752 CAUTION: Ensure that retainers (2) and rocker arms (4) are not overlapped when torquing bolts. CAUTION: Verify that pushrod is installed into rocker arm (4) and tappet correctly while installing rocker shaft assembly. Recheck after rocker shaft has been torqued to specification. CAUTION: The rocker shaft assemblies are not interchangeable between intake and exhaust. The intake rocker arms are marked with the letter "I". 3. Install rocker shaft assemblies in the same order as removed. 4. Tighten the rocker shaft bolts to 22 Nm (195 inch lbs.) torque, using the sequence provided. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 1753 5. Remove pushrod retaining plate (1) special tool 9070. 6. Install cylinder head cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair COVER - CYLINDER HEAD REMOVAL 1. Disconnect battery negative cable. 2. Disconnect ignition coil connector (1). 3. Remove ignition coil retaining bolts (3). 4. Remove ignition coil (1). 5. Remove cylinder head cover retaining bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1757 6. Remove cylinder head cover (1). NOTE: The gasket (2) may be used again, provided no cuts, tears, or deformation has occurred. INSTALLATION CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: DO NOT allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1758 1. Clean cylinder head cover (1) and both sealing surfaces (1,4,). Inspect and replace gasket (2) as necessary. 2. Install cylinder head cover and hand start all fasteners. Verify that all double ended studs (3) are in the correct location. 3. Tighten cylinder head cover bolts and double ended studs to 8 Nm (70 inch lbs.). Begin torque sequence in the middle of head cover and torque bolts moving outward in a crisscross pattern from top to bottom. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1759 4. Before installing coil(s), apply dielectric grease to inside of spark plug boots (1). 5. Install ignition coils. 6. Torque fasteners (3) to 7 Nm (62 inch lbs.). 7. Connect, ignition coil electrical connectors (1). 8. Install PCV hose. 9. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Description and Operation Valve Guide: Description and Operation DESCRIPTION - VALVE GUIDES The valve guides are made of powdered metal and are pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair SPRINGS - VALVE REMOVAL 1. Disconnect negative battery cable. 2. Remove air cleaner assembly. 3. Remove air intake resonator. 4. Remove ignition coil connector (1). 5. Remove ignition coils (2). 6. Remove one spark plug. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1766 7. Remove cylinder head cover (1) using the sequence shown. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1767 CAUTION: The piston must be at TDC, and both valves closed on the cylinder to be serviced. NOTE: If removing intake valve spring, install special tool #9070, pushrod retaining plate (1), to retain the intake pushrods; (2). 8. Remove exhaust/intake rocker arm shafts using the sequence shown. 9. Install rocker arm shaft (1) special tool #9065. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1768 10. Install spring compressor (1,3,), special tool #9065, and exhaust adapter arm (1) tool #9065 if needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1769 NOTE: All valve springs and seals are removed in the same manner. 11. Insert air hose (1) into spark plug hole and charge cylinder with air. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks. 12. Compress valve spring with valve spring compressor (3) tool #9065 and remove valve retainer locks. 13. Release spring compressor (3) and remove valve spring. NOTE: The valve springs are interchangeable between intake and exhaust. 14. Remove valve seal. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1770 1. Install valve seal. 2. Install valve spring. 3. Using special tool #9065 (1,3,), compress valve spring and install valve spring retainer and locks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1771 4. Release air charge in cylinder (1). 5. Remove spring compressor tool #9065 (3). CAUTION: Verify that the pushrods; are fully seated into lifter and rocker arm. Recheck after rocker arm shaft has been torqued to specification. 6. Install rocker arm shaft and pushrods. 7. Tighten the rocker shaft bolts to 22 Nm (195 inch lbs.) torque, using the rocker shaft torque sequence. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1772 8. Remove special tool #9070, pushrod retaining plate (1), if used. 9. Install cylinder head cover (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 1773 10. Tighten cylinder head cover bolts and double ended studs. 11. Install spark plugs. 12. Install ignition coil on plug (2), and torque fasteners (3) to 7 Nm (62 inch lbs.). 13. Install ignition coil connectors (4). 14. Install air intake resonator. 15. Install air cleaner assembly. 16. Connect negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation Valve: Description and Operation VALVES & SEATS - INTAKE/EXHAUST DESCRIPTION Both the intake and exhaust valves are made of steel. The intake valve is 50.93 mm (2.00 inches) in diameter and the exhaust valve is 39.53 mm (1.55 inches) in diameter. All valves use three bead lock keepers to retain the springs and promote valve rotation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation VALVES & SEATS - INTAKE/EXHAUST REMOVAL 1. Remove the cylinder head. 2. Compress valve springs using Valve Spring Compressor Tool special tool #C-3422 and adapter 8464. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. INSTALLATION 1. Clean valves thoroughly Discard burned, warped and cracked valves. 2. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 3. Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. 4. Coat valve stems with lubrication oil and insert them in cylinder head. 5. If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. 6. Install new seals on all valve guides. Install valve springs and valve retainers. 7. Compress valve springs with Valve Spring Compressor Tool special tool #C-3422 and adapter 8464, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. 8. Install cylinder head. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 1779 Valve: Service and Repair Refacing Valves & Seats REFACING NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 1. Using a suitable dial indicator measure the center of the valve seat Total run out must not exceed 0.051 mm (0.002 inch). 2. Apply a small amount of Prussian blue to the valve seat, insert the valve into the cylinder head, while applying light pressure on the valve rotate the valve. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone. 3. When the seat is properly positioned the width of the intake seat must be 1.018 - 1.62 mm (0.0464 - 0.0637 inch) and the exhaust seat must be 1.48 - 1.92 mm (0.058 - 0.075 inch). 4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 46.0 mm (1.81 inch). VALVE FACE AND VALVE SEAT ANGLE CHART 5. The valve seat must maintain an angle of 44.5 - 45.0 degrees angle. 6. The valve face must maintain a face angle of 45.0 - 45.5 degrees angle Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Drive Belt: Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1784 Drive Belt: Testing and Inspection BELT-DRIVE DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT VISUAL DIAGNOSIS NOTE: 5.9L Diesel Engine - If a belt is broken or frayed, inspect engine speed sensor (located near the crankshaft damper) for damage. When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. ACCESSORY DRIVE BELT DIAGNOSIS CHART (part 1) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1785 ACCESSORY DRIVE BELT DIAGNOSIS CHART (part 2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1786 ACCESSORY DRIVE BELT DIAGNOSIS CHART (part 3) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1787 Drive Belt: Service and Repair BELT-DRIVE REMOVAL 5.7L ENGINE The 5.7L engine accessory drive system consists of: A/C Compressor or Idler Pulley (1) - Fan Drive Pulley (2) - Power Steering Pump (3) - Crankshaft Pulley (4) - Idler Assembly (5) - Tensioner Assembly (6) - Accessory Drive Belt (7) - Generator (8) - Idler Pulley (9) 1. Remove the air intake tube between intake manifold and air filter assembly. 2. Insert a suitable square drive ratchet into the square hole on belt tensioner arm. 3. Release the belt tension by rotating the tensioner clockwise. Rotate belt tensioner until belt can be removed from pulleys. 4. Remove belt. 5. Gently release tensioner. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1788 The 5.7L engine accessory drive system consists of: A/C Compressor or Idler Pulley (1) - Fan Drive Pulley (2) - Power Steering Pump (3) - Crankshaft Pulley (4) - Idler Assembly (5) - Tensioner Assembly (6) - Accessory Drive Belt (7) - Generator (8) - Idler Pulley (9) NOTE: When installing accessory drive belt onto pulleys, make sure that belt is properly routed and all V-grooves make proper contact with pulleys. 1. Position the drive belt over all pulleys except for the water pump pulley. 2. Rotate tensioner clockwise and slip the belt over the water pump pulley. 3. Gently release tensioner. 4. Install the air intake tube between intake manifold and air filter assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation Drive Belt Tensioner: Description and Operation TENSIONER-BELT DESCRIPTION Correct drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension. All engines are equipped with an automatic belt tensioner. The tensioner maintains correct belt tension at all times. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. OPERATION The automatic belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and pulley to press against the drive belt. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Page 1792 Drive Belt Tensioner: Service and Repair TENSIONER-BELT REMOVAL 5.7L ENGINE 1. Remove accessory drive belt. 2. Remove tensioner (1) and mounting bracket. 3. Remove the tensioner assembly from the mounting bracket. INSTALLATION 1. Install tensioner (1) on to the mounting bracket. Tighten bolt (2) to 41 Nm (30 ft. lbs.). 2. Install tensioner and bracket assembly 3. Install accessory drive belt. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation Engine Mount: Description and Operation COVER - STRUCTURAL DESCRIPTION The structural dust cover is made of die cast aluminum and joins the lower half of the transmission bell housing to the engine. OPERATION The structural cover provides additional powertrain stiffness and reduces noise and vibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cover-Structural Engine Mount: Service and Repair Cover-Structural COVER - STRUCTURAL REMOVAL 1. Raise vehicle on hoist. CAUTION: On manual transmission vehicles, the 7/16 inch engine block to clutch housing bolts must be loosened before removal of the structural dust cover (1). Clutch housing distortion will occur if this procedure is not followed. 2. Remove the bolts retaining structural cover (1,2). 3. Remove the structural cover. INSTALLATION AUTOMATIC TRANSMISSION CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover. 1. Position the structural cover in the vehicle. 2. Install all four bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the four cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cover-Structural > Page 1798 4. Torque the (4) structural dust cover bolts that go into the transmission to 6 - 11 Nm (50 - 100 inch lbs.). 5. Torque the (4) structural dust cover bolts that go into the engine block to 6 - 11 Nm (50 - 100 inch lbs.). 6. Starting with the two rear cover-to-engine bolts, tighten bolts (1) to 54 Nm (40 ft. lbs.), then tighten bolts (2) and (3) to 54 Nm ( 40 ft. lbs.) in the sequence shown. 7. Install the exhaust pipe on left hand exhaust manifold. 8. Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20 - 26 Nm (15 - 20 ft. lbs.). MANUAL TRANSMISSION CAUTION: The 7/16 inch engine block to clutch housing bolts must be loosened before removal/installation of the structural dust cover. Clutch housing distortion will occur if this procedure is not followed. 1. Position the structural cover in the vehicle. CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover, and engine noise. 2. Install all bolts retaining the cover-to-engine. DO NOT tighten the bolts at this time. 3. Install the cover-to-transmission bolts. Do NOT tighten at this time. CAUTION: The structural cover must be held tightly against the corner formed by the engine and the transmission clutch housing during tightening sequence. Failure to do so may cause damage to the cover and engine noise. 4. Torque the (2) structural dust cover bolts that go into the clutch housing to 6 - 11 Nm (50 - 100 inch lbs.). 5. Torque the (4) structural dust cover bolts that go into the engine block to 6 - 11 Nm (50 - 100 inch lbs.). 6. Torque the structural cover bolt that is closest to the rear face of block on the passenger side of block to 54 Nm (40 ft. lbs.). 7. Torque the structural cover bolt that is closest to the front face of block on the drivers side to 54 Nm (40 ft. lbs.). 8. Torque the remaining (2) structural cover bolts that go into the block in an X pattern to 54 Nm (40 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cover-Structural > Page 1799 9. Torque the structural cover bolts that go into the clutch housing to 54 Nm (40 ft. lbs.). 10. Torque the 7/16 inch engine block to clutch housing bolts to 68 Nm (50 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cover-Structural > Page 1800 Engine Mount: Service and Repair Mount-Front MOUNT-FRONT REMOVAL 2WD 1. Disconnect negative battery cable. 2. Raise vehicle. 3. Remove engine mount through bolts. 4. Raise engine using engine support fixture special tool #8534. 5. Remove engine mount to insulator bolts (1). 6. Remove insulator (2) from engine. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cover-Structural > Page 1801 1. Install insulator (2) on the engine. NOTE: For mount to engine block and left engine bracket to front axle bolts, apply Mopar Lock and Seal Adhesive, Medium Strength Threadlocker. 2. Install upper and lower mount mounting bolts. Tighten bolts to 61 Nm (45 ft. lbs.). 3. Lower the engine using engine support fixture special tool #8534. 4. Install mount through bolts. 5. Tighten through bolts on both sides to 61 Nm (45 ft. lbs.). 6. Lower vehicle. 7. Connect negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Cover-Structural > Page 1802 Engine Mount: Service and Repair Mount-Rear MOUNT-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Using a suitable jack, support transmission. 3. Remove the nuts from the transmission mount. 4. Remove the two bolts that attach the transmission mount to the engine bracket. 5. Raise the transmission enough to remove the mount from the crossmember. 6. Remove the mount. INSTALLATION NOTE: Threadlocking compound must be applied to the bolts before installation. 1. Install the two bolts that attach the transmission mount to the transmission bracket. 2. Torque the bolts to 61 Nm (45 ft. lbs.) torque. 3. Lower the transmission so the transmission mount rests on the crossmember, and the studs of the transmission mount are aligned in the slots in the crossmember. 4. Install the nuts onto the transmission mount studs through the crossmember access slot. 5. Torque the nuts to 54 Nm (40 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Curb Idle .............................................................................................................................................. ............................................ 25 kPa (4 psi) minimum 3000 rpm .......................................................... ......................................................................................................................... 170 - 758 kPa (25 110 psi) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 1807 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE 1. Remove oil pressure sending unit and install gauge assembly C-3292. 2. Run engine until thermostat opens. 3. Oil Pressure: ^ Curb Idle - 25 kPa (4 psi) minimum ^ 3000 rpm - 170 - 758 kPa (25 - 110 psi) 4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1812 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ..................................................... 6.6Liters (7.0 Qt) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1815 Engine Oil: Fluid Type Specifications An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. For 5.7L engines SAE 5W-20 engine oil is recommended for all operating temperatures. These engine oils improve low temperature starting and vehicle fuel economy. Refer to your engine oil filler cap for the recommended engine oil viscosity for your vehicle. Vehicles with 5.7L engines equipped with Multiple Displacement System (MDS) must use SAE 5W-20 oil. Failure to do so may result in improper operation of the Multiple Displacement System (MDS). Refer to the engine oil filler cap for the recommended engine oil viscosity for each vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1816 Engine Oil: Testing and Inspection ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 1817 Engine Oil: Service and Repair ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to Service Precautions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil Service Oil Filter: Service and Repair Engine Oil Service ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to Service Precautions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Engine Oil Service > Page 1822 Oil Filter: Service and Repair Removal and Installation FILTER - ENGINE OIL REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. DaimlerChrysler Corporation recommends a Mopar or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter (3). 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket (2) with engine oil. 2. Thread filter (3) onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°, do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts ........................................................................................................................................ ................................................ 12 Nm (105 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1826 Oil Pan: Service and Repair PAN - ENGINE OIL REMOVAL 1. Disconnect the negative battery cable. 2. Install engine support fixture special tool #8534. Do not raise engine at this time. 3. For 2WD vehicles, Remove both engine mount to frame through bolts. 4. For 4WD vehicles, Loosen both left and right side engine mount bracket to mount bolts, and remove the lower bolt on each side. The upper hole in the engine bracket is slotted. 5. Remove the structural dust cover (1). 6. Drain engine oil. 7. Remove the front crossmember. CAUTION: Only raise the engine enough to provide clearance for oil pan removal. Check for proper clearance at fan shroud to fan and cowl to intake manifold. 8. Raise engine using special tool #8534 to provide clearance to remove oil pan. 9. Remove the nuts from the transmission mount to crossmember. 10. Using suitable transmission jack, raise the transmission approximately 3 inches off of the crossmember. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1827 11. Remove the oil pan mounting bolts using the sequence above, and remove oil pan. NOTE: The double ended oil pan studs must be installed in the same location that they were removed from. 12. Unbolt oil pump pickup tube and remove tube. NOTE: When the oil pan is removed, a new oil pan gasket/windage tray assembly must be installed. The old gasket cannot be reused. 13. Discard the integral windage tray and gasket and replace. INSTALLATION 1. Clean the oil pan gasket mating surface of the block and oil pan. NOTE: Mopar Engine RTV must be applied to the 4 T-joints, (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations. 2. Apply Mopar Engine RTV at the 4 T-joints. NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old gasket cannot be reused. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1828 3. Install a new integral windage tray and gasket. 4. Reinstall the oil pump pickup tube with new O-ring. Tighten tube to pump fasteners to 28 Nm (250 inch lbs.). NOTE: The double ended oil pan studs must be installed in the same location that they were removed from. 5. Position the oil pan and install the mounting bolts and studs. Tighten the mounting bolts to 12 Nm (105 inch lbs.), using the sequence above. 6. Lower the transmission onto the crossmember. Install nuts, and tighten. 7. Lower the engine into mounts using special tool #8534. 8. For 2WD vehicles, Install both the left and right side engine mount through bolts. Tighten the nuts to 68 Nm (50 ft. lbs.). 9. For 4WD vehicles, Install both the left and right side engine mount bracket to mount bolts. Tighten the nuts to 68 Nm (50 ft. lbs.). 10. Remove special tool #8534. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 1829 11. Install the structural dust cover (1). 12. Install the front crossmember. 13. Fill engine oil. 14. Reconnect the negative battery cable. 15. Start engine and check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT10. On SRT10 models the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from 0 psi to 100 psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT10 the oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale. On SRT10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation (except SRT10) or to the red zone (SRT10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1838 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1839 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1840 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1841 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1842 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1843 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1844 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1845 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1846 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1847 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1848 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1849 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1850 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1851 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 Switch - Oil Pressure (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Curb Idle .............................................................................................................................................. ............................................ 25 kPa (4 psi) minimum 3000 rpm .......................................................... ......................................................................................................................... 170 - 758 kPa (25 110 psi) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 1866 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE 1. Remove oil pressure sending unit and install gauge assembly C-3292. 2. Run engine until thermostat opens. 3. Oil Pressure: ^ Curb Idle - 25 kPa (4 psi) minimum ^ 3000 rpm - 170 - 758 kPa (25 - 110 psi) 4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1870 Sensor - Engine Oil Temperature (5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1871 Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. Oil Temperature Sensor Tests (Part 1) Oil Temperature Sensor Tests (Part 2) 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Intake Manifold-Bolts ........................................................................................................................... .............................................. 12 Nm (105 inch lbs.) From the middle bolts towards the outside in a crisscross pattern Throttle Body-Bolts .............................................................................................................................. ............................................... 12 Nm (105 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1875 Intake Manifold: Description and Operation MANIFOLD - INTAKE DESCRIPTION The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1876 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water at the suspected leak area. 3. If a change in RPM is observed the area of the suspected leak has been found. 4. Repair as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1877 Intake Manifold: Service and Repair MANIFOLD - INTAKE REMOVAL 1. Disconnect negative cable from battery. 2. Remove resonator assembly and air inlet hose. 3. Disconnect electrical connectors for the following components: ^ Manifold Absolute Pressure (MAP) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Throttle Position (TPS) Sensor ^ Coolant Temperature (CTS) Sensor 4. Disconnect brake booster hose and positive crankcase ventilation (PCV) hose. 5. Remove generator and set aside. NOTE: It is not necessary to remove lines or remove freon from A/C compressor. 6. Remove air conditioning compressor and set aside. 7. Bleed fuel system. 8. Remove intake manifold retaining fasteners in a crisscross pattern starting from the outside bolts and ending at the middle bolts. 9. Remove intake manifold and IAFM as an assembly CLEANING NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced. Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry. INSPECTION 1. Inspect the intake sealing surface for cracks, nicks and distortion. 2. Inspect the intake manifold vacuum hose fittings for looseness or blockage. 3. Inspect the manifold to throttle body mating surface for cracks, nicks and distortion. INSTALLATION 1. Install intake manifold seals. 2. Position intake manifold and IAFM. 3. Install intake manifold retaining bolts, and tighten in sequence from the middle bolts towards the outside in a crisscross pattern. Torque fasteners to 12 Nm (105 inch lbs.). 4. Connect electrical connectors for the following components: ^ Manifold Absolute Pressure (MAP) Sensor ^ Intake Air Temperature (IAT) Sensor ^ Throttle Position (TPS) Sensor ^ Coolant Temperature (CTS) Sensor ^ Idle Air Control (IAC) Motor 5. Install generator. 6. Install A/C compressor. 7. Connect Brake booster hose and Positive crankcase ventilation (PCV) hose. 8. Install resonator assembly and air inlet hose. 9. Connect negative cable to battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT10. On SRT10 models the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from 0 psi to 100 psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT10 the oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale. On SRT10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation (except SRT10) or to the red zone (SRT10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection Crankshaft Main Bearing Seal: Testing and Inspection REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: 1. Disconnect the battery 2. Raise the vehicle. 3. Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak: a. Circular spray pattern generally indicates seal leakage or crankshaft damage. b. Where leakage tends to run straight down, possible causes are a porous block, camshaft bore cup plugs, oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. 4. If no leaks are detected, pressurized the crankcase as outlined in Inspection (Engine oil Leaks in general) CAUTION: Do not exceed 20.6 kPa (3 psi). 5. If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks or scratches. The crankshaft seal flange is specially machined to complement the function of the rear oil seal. 6. For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1886 Crankshaft Main Bearing Seal: Service and Repair SEAL - CRANKSHAFT OIL - REAR REMOVAL NOTE: This procedure can be performed in vehicle. 1. If being performed in vehicle, remove the transmission. 2. Remove the flexplate. NOTE: The crankshaft oil seal CAN NOT be reused after removal. NOTE: The crankshaft rear oil seal remover Special Tool 8506 must be installed deeply into the seal. Continue to tighten the removal tool into the seal until the tool can not be turned farther. Failure to install tool correctly the first time will cause tool to pull free of seal without removing seal from engine. 3. Using Special Tool 8506 (1), remove the crankshaft rear oil seal (2). INSTALLATION CAUTION: The rear seal must be installed dry for proper operation. Do not lubricate the seal lip or outer edge. 1. Position the plastic seal guide (2) onto the crankshaft rear face. Then position the crankshaft rear oil seal (3) onto the guide. 2. Using Special Tools 8349 Crankshaft Rear Oil Seal Installer (1) and C-4171 Driver Handle, with a hammer, tap the seal (3) into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Testing and Inspection > Page 1887 3. Install the flexplate. 4. Install the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair SEAL - CRANKSHAFT OIL - FRONT REMOVAL 1. Disconnect negative cable from battery. 2. Remove accessory drive belt. 3. Drain cooling system. 4. Remove upper radiator hose. 5. Remove radiator shroud attaching fasteners. 6. Remove radiator cooling fan and shroud. 7. Remove crankshaft damper bolt. 8. Remove damper using Special Tools 8513A Insert (2) and 1023 Three Jaw Puller (1). 9. Using Special Tool 9071 (1), remove crankshaft front seal (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 1891 CAUTION: The front crankshaft seal must be installed dry. Do not apply lubricant to sealing lip or to outer edge. 1. Using Special Tool 9072 and 8512A, install crankshaft front seal. CAUTION: To prevent severe damage to the Crankshaft or Damper, thoroughly clean the damper bore and the crankshaft nose before installing Damper. 2. Install vibration damper. 3. Install radiator cooling fan and shroud. 4. Install upper radiator hose. 5. Install accessory drive belt refer. 6. Refill cooling system. 7. Connect negative cable to battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation SEALS - VALVE GUIDE DESCRIPTION The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1901 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1902 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1903 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1904 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1905 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1906 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1907 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1908 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1909 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1910 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1911 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1912 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1913 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1914 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1915 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1916 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1917 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1918 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1919 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1920 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 1921 Switch - Oil Pressure (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1928 Sensor - Engine Oil Temperature (5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Page 1929 Oil Temperature Sensor/Switch: Testing and Inspection 1. Disconnect the engine wire harness connector from the oil temperature sensor. Oil Temperature Sensor Tests (Part 1) Oil Temperature Sensor Tests (Part 2) 2. Using an ohmmeter and a test thermometer, test the resistance versus the oil temperature relationship of the sensor between the two terminals of the sensor as shown in the Oil Temperature Sensor Tests table. 3. If the sensor fails any of these tests, replace the faulty oil temperature sensor as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service Precautions Timing Chain: Service Precautions Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation Timing Chain: Service and Repair Timing Cover Removal and Installation COVER - TIMING REMOVAL 1. Disconnect the battery negative cable. 2. Remove the engine cover (1). 3. Remove air cleaner assembly. 4. Drain cooling system. 5. Remove accessory drive belt. 6. Remove fan and fan drive assembly. 7. Remove coolant bottle and washer bottle. 8. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge freon. 9. Remove A/C compressor and set aside. 10. Remove the generator. 11. Remove upper radiator hose. 12. Disconnect both heater hoses at timing cover. 13. Disconnect lower radiator hose at engine. 14. Remove accessory drive belt tensioner and both idler pulleys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1936 15. Remove crankshaft damper (2). NOTE: Do not remove the hoses from the power steering pump. 16. Remove power steering pump and set aside. 17. Remove the dipstick support bolt. 18. Drain the engine oil. 19. Remove the oil pan and pick up tube. NOTE: It is not necessary to remove water pump for timing cover removal. 20. Remove timing cover bolts and remove cover. 21. Verify that timing cover slide bushings (1) are located in timing cover. INSTALLATION 1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1937 2. Verify that the slide bushings (1) are installed in timing cover. 3. Install cover and new gasket. Tighten fasteners to 28 Nm (250 inch lbs.). NOTE: The large lifting stud is torqued to 55 Nm (40 ft. lbs.). 4. Install the oil pan and pick up tube. 5. Install the A/C compressor. 6. Install the generator. 7. Install power steering pump. 8. Install the dipstick support bolt. 9. Install the thermostat housing. 10. Install crankshaft damper. 11. Install accessory drive belt tensioner assembly and both idler pulleys. 12. Install radiator lower hose. 13. Install both heater hoses. 14. Install radiator fan shroud. 15. Install the fan and fan drive assembly 16. Install the accessory drive belt. 17. Install the coolant bottle and washer bottle. 18. Install the upper radiator hose. 19. Install the air cleaner assembly. 20. Fill cooling system. 21. Refill engine oil. 22. Connect the battery negative cable. 23. Install the engine cover (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1938 Timing Chain: Service and Repair Timing Chain Removal and Installation TIMING CHAIN & SPROCKETS REMOVAL 1. Disconnect battery negative cable. 2. Drain cooling system. 3. Remove Timing Chain Cover (1). Timing Component Alignment Marks-5.7L 4. Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and keyways as shown. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00 (2). The crankshaft keyway must be clocked at 2:00 (3). The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1939 5. Remove oil pump. 6. Retract tensioner shoe (1) until hole in shoe lines up with hole in bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1940 7. Slide a suitable pin (1) into the holes. 8. Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets (2). 9. If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1941 1. If tensioner (1) assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 28 Nm (250 inch lbs.). 2. Retract tensioner (2) if required. CAUTION: The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links. CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00. 3. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. 4. Place timing chain around both sprockets. 5. Lift sprockets and chain (keep sprockets tight against the chain in position as shown). 6. Slide both sprockets (2,3) evenly over their respective shafts and check alignment of timing marks. 7. Install the camshaft bolt. Tighten the bolt to 122 Nm (90 ft. lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1942 8. Remove tensioner pin. (1) Again, verify alignment of timing marks. 9. Install the oil pump. 10. Install the oil pan and pick up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Cover Removal and Installation > Page 1943 11. Install the timing chain cover. 12. Refill engine oil. 13. Fill cooling system. 14. Connect battery negative cable. 15. Start engine and check for oil and coolant leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Description and Operation Timing Chain Tensioner: Description and Operation TENSIONER - TIMING CHAIN DESCRIPTION The timing chain tensioner is a stamped steel constant tension mechanical design. It is mounted to the front of the engine, behind the timing chain drive. OPERATION The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon covered spring steel arm presses on the timing chain maintaining the correct chain tension. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Component Alignment Marks > Component Information > Locations Timing Component Alignment Marks-5.7L Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Case Cover-Bolts ........................................................................................................................................................... 28 Nm (250 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1953 Timing Cover: Service and Repair COVER - TIMING REMOVAL 1. Disconnect the battery negative cable. 2. Remove the engine cover (1). 3. Remove air cleaner assembly. 4. Drain cooling system. 5. Remove accessory drive belt. 6. Remove fan and fan drive assembly. 7. Remove coolant bottle and washer bottle. 8. Remove fan shroud. NOTE: It is not necessary to disconnect A/C lines or discharge freon. 9. Remove A/C compressor and set aside. 10. Remove the generator. 11. Remove upper radiator hose. 12. Disconnect both heater hoses at timing cover. 13. Disconnect lower radiator hose at engine. 14. Remove accessory drive belt tensioner and both idler pulleys. 15. Remove crankshaft damper (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1954 NOTE: Do not remove the hoses from the power steering pump. 16. Remove power steering pump and set aside. 17. Remove the dipstick support bolt. 18. Drain the engine oil. 19. Remove the oil pan and pick up tube. NOTE: It is not necessary to remove water pump for timing cover removal. 20. Remove timing cover bolts and remove cover. 21. Verify that timing cover slide bushings (1) are located in timing cover. INSTALLATION 1. Clean timing chain cover and block surface. NOTE: Always install a new gasket on timing cover. 2. Verify that the slide bushings (1) are installed in timing cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 1955 3. Install cover and new gasket. Tighten fasteners to 28 Nm (250 inch lbs.). NOTE: The large lifting stud is torqued to 55 Nm (40 ft. lbs.). 4. Install the oil pan and pick up tube. 5. Install the A/C compressor. 6. Install the generator. 7. Install power steering pump. 8. Install the dipstick support bolt. 9. Install the thermostat housing. 10. Install crankshaft damper. 11. Install accessory drive belt tensioner assembly and both idler pulleys. 12. Install radiator lower hose. 13. Install both heater hoses. 14. Install radiator fan shroud. 15. Install the fan and fan drive assembly 16. Install the accessory drive belt. 17. Install the coolant bottle and washer bottle. 18. Install the upper radiator hose. 19. Install the air cleaner assembly. 20. Fill cooling system. 21. Refill engine oil. 22. Connect the battery negative cable. 23. Install the engine cover (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1960 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1961 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 1965 Idle Speed: Description and Operation 5.7L: A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Fig. 1 AIR CLEANER COVER Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1970 Fig. 2 AIR CLEANER HOUSING 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips (5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4 Nm (40 inch lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1971 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1980 right front side of the engine block (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1981 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1982 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1983 Firing Order ......................................................................................................................................... ......................................................... 1-8-4-3-6-5-7-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plugs Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1992 Spark Plug: Mechanical Specifications Gap ...................................................................................................................................................... ................................................... 0.045 in. (1.14mm) Torque ................................................................................................................................................. ................................................... 13 ft. lbs. (18 N-m) Torque critical design. Do not exceed 15 ft. lbs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1993 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1994 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L engines. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. This is especially true when plugs are equipped with tapered seats. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation REMOVAL Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary. 5. Inspect spark plug condition. INSTALLATION NOTE: The 4.7L is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 27 N.m (20 ft.lbs.). 3.7L & 4.7L. 3. The 5.7L is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. torque. Tighten spark plugs to 18 N.m (13 ft.lbs). NOTE: 5.7L does not use an O-ring 4. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 5. Install ignition coil(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 1997 Spark Plug: Service and Repair Cleaning CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2001 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump to Timing Chain Case Cover-Bolts .................................................................................................................................. 28 Nm (250 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2005 Water Pump: Description and Operation PUMP-WATER DESCRIPTION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2006 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2007 Water Pump: Service and Repair WATER PUMP REMOVAL 5.7L ENGINE 1. Disconnect negative battery cable. 2. Drain coolant. 3. Remove serpentine belt. 4. Remove fan clutch assembly. 5. Remove coolant fill bottle. 6. Disconnect washer bottle wiring and hose. 7. Remove fan shroud assembly. 8. Remove A/C compressor and generator brace. 9. Remove idler pulleys. 10. Remove belt tensioner assembly. 11. Remove upper and lower radiator hoses. 12. Remove heater hoses. 13. Remove water pump mounting bolts and remove pump. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2008 1. Install water pump and mounting bolts. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 2. Install heater hoses. 3. Install upper and lower radiator hoses. 4. Install belt tensioner assembly 5. Install idler pulleys. 6. Install A/C compressor and alternator brace. Tighten bolt and nuts to 28 Nm (21 ft. lbs.). 7. Install fan shroud assembly. 8. Connect washer bottle wiring and hose. 9. Install coolant fill bottle. 10. Install fan clutch assembly. 11. Install serpentine belt. 12. Connect negative battery cable. 13. Fill coolant. 14. Pressure test coolant system Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2014 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity ................................................................................................................................. ....................................................... 18.7 qts. (17.7 L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2017 Coolant: Fluid Type Specifications Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology) or equivalent. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2018 Coolant: Description and Operation ENGINE COOLANT DESCRIPTION WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. ETHYLENE-GLYCOL MIXTURES CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 year/100,000 Mile Formula (ethylene-glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain a freeze point of -37°C (-35°F). The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22°C (-8°F). PROPYLENE-GLYCOL MIXTURES It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32°C (-26°F). 5°C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125°C (257°F) at 96.5 kPa (14 psi), compared to 128°C (263°F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up on a cooling system designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. HOAT COOLANT WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE-GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASE COOLANT PROPERLY, CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2019 properly mixed coolant solution. CAUTION: Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. COOLANT SELECTION AND ADDITIVES The use of aluminum cylinder blocks, cylinder heads and water pumps requires special corrosion protection. Only Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (glycol base coolant with corrosion inhibitors called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% distilled water to obtain to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. OPERATION Coolant flows through the engine block absorbing the heat from the engine, then flows to the radiator where the cooling fins in the radiator transfers the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by mixture ratio of coolant to water. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2020 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37°C (-34°F). to -46°C (-50°F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer Tool 8286 will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation CONTAINER-COOLANT RECOVERY-GAS ENGINES DESCRIPTION The coolant reserve/overflow tank is mounted on top of the fan shroud, and is made of high temperature plastic. OPERATION The coolant reserve/overflow system works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of coolant to keep coolant free of trapped air. It provides a volume for expansion and contraction of coolant. It also provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 2024 Coolant Reservoir: Service and Repair CONTAINER-COOLANT RECOVERY REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Disconnect washer pump electrical connector. 2. Remove recovery hose (3) from radiator (4). 3. Remove the coolant container to fan shroud mounting bolts (1). 4. Tilt the container (2) backward towards the engine to disengage the mounting pin locking features and lift the container away from the fan shroud (5). INSTALLATION 1. Align the coolant container mounting pins into the slots on the fan shroud (5) and push the container onto the fan shroud. 2. Secure the container to the fan shroud with the bolts (1). Tighten to 8.5 Nm (75 inch lbs.). NOTE: Ensure that the locking feature on the mounting pins has engaged. 3. Connect the recovery hose (3) to the radiator (4). 4. Connect washer pump electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation Fan Clutch: Description and Operation FAN DRIVE VISCOUS DESCRIPTION 3.7L/4.7L/5.7L ENGINE (BI-METAL COIL TYPE) The thermal Bi-Metal Coil type viscous fan drive is a silicone fluid-filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. OPERATION A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown). This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed. Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling. Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 2029 Fan Clutch: Service and Repair VISCOUS FAN DRIVE REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Do Not attempt to remove the fan/viscous fan drive assembly from the vehicle at this time. CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. 2. Disconnect negative battery cable from battery. 3. Remove coolant reserve/overflow container from fan shroud and lay aside. Do Not disconnect the hoses or drain coolant from the container. 4. Using Special Tool 6958, remove the fan blade/viscous fan drive assembly from the water pump by turning the mounting nut counterclockwise as viewed from the front. Threads on the viscous fan drive are RIGHT-HAND. 5. Do Not unbolt the fan blade assembly from viscous fan drive at this time. 6. Remove the fan shroud-to-radiator mounting bolts. 7. Pull the lower shroud mounts out of the radiator tank clips. 8. Remove the fan shroud and fan blade/viscous fan drive assembly as a complete unit from vehicle. 9. After removing the fan blade/viscous fan drive assembly, do not place the viscous fan drive in a horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant. CAUTION: Do not remove water pump pulley-to-water pump bolts. This pulley is under spring tension. 10. Remove four bolts securing fan blade assembly to viscous fan drive. CAUTION: Some engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives. Installation of the wrong fan or viscous fan drive can result in engine overheating. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 2030 NOTE: Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive. 1. Install fan blade assembly to the viscous fan drive. Tighten the bolts to 24 Nm (18 ft. lbs.) torque. 2. Position the fan shroud and the fan blade/viscous fan drive assembly to the vehicle as a complete unit. 3. Install the fan shroud. 4. Using Special Tool 6958, install the fan blade/viscous fan drive assembly to the water pump shaft. Tighten mounting nut to 50 Nm (37 ft. lbs.). 5. Install the coolant reserve/overflow container to the fan shroud. 6. Connect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2035 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2036 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2040 Heater Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2041 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secures the heater core bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines except SRT10. On SRT10 models, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 260° F in all other markets. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. On all vehicles except SRT10 the engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale. On SRT10 the gauge graphics are black against silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM or ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation Radiator: Description and Operation RADIATOR DESCRIPTION The radiator is a aluminum cross-flow design with horizontal tubes through the radiator core and vertical plastic side tanks. This radiator does not contain an internal transmission oil cooler. OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 2049 Radiator: Testing and Inspection RADIATOR COOLANT FLOW Use the following procedure to determine if coolant is flowing through the cooling system. 1. Idle engine until operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and coolant is flowing to the radiator. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER THE RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO THE FIRST STOP. THIS WILL ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK. 2. Drain a small amount of coolant from the radiator until the ends of the radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If coolant is flowing past the exposed tubes, the coolant is circulating. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 2050 Radiator: Service and Repair RADIATOR REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Disconnect battery negative cables. WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. 2. Drain the cooling system. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS. CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter and the correct width. 3. Remove the hose clamps and hoses from radiator. 4. Remove the coolant reserve/overflow tank hose from the radiator filler neck. 5. Remove the coolant reserve/overflow tank from the fan shroud (pull straight up). The tank slips into slots on the fan shroud. 6. Unclip the power steering hoses from the fan shroud. 7. Disconnect the electrical connectors at the wind shield washer reservoir tank and remove the tank. 8. Remove the fan shroud mounting bolts and pull up and out of the radiator tank clips. Position shroud rearward over the fan blades towards engine. 9. Disconnect the transmission cooler lines from the transmission cooler, then plug the transmission lines and cooler to prevent leakage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 2051 10. Disconnect the power steering lines from the power steering cooler, then plug the power steering lines and cooler to prevent leakage. 11. Remove the two radiator upper mounting bolts. 12. Lift the radiator straight up and out of the engine compartment. Take care not to damage cooling fins or tubes on the radiator and oil coolers when removing. NOTE: The radiator is equipped with one alignment dowel on the bottom of the outlet tank and one retaining bracket on the front side of the inlet tank. Both features have rubber insulators attached to them that must be present. The alignment dowel fits into a hole at the bottom of the front end sheet metal vertical support post and the support bracket rests on top of the lower radiator closure tube. CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and oil cooler fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or oil coolers of debris. INSPECTION Inspect the radiator side tanks for cracks, and broken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leakage and/or deteriorating seals. Inspect radiator core for corroded, bent or missing cooling fins. Inspect the core for bent or damaged cooling tubes. INSTALLATION 1. Position the fan shroud over the fan blades rearward towards engine. 2. Install the rubber insulators to the lower radiator mounting features (alignment dowel and support bracket at the lower part of the radiator). 3. Lower the radiator into position while guiding the alignment dowel into the vertical post bracket. Position and seat the lower radiator support bracket onto the lower radiator closure tube. 4. Install the upper radiator mounting bolts. Tighten bolts to 10 Nm (90 inch lbs.). 5. Connect the lower radiator hose and install the clamp in the proper position. 6. Connect the power steering hoses to the power steering oil cooler and install the clamps. 7. Connect the transmission oil cooler lines to the transmission oil cooler and install the secondary latches. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 2052 8. Position the fan shroud into the mounting clips on the radiator tanks and secure with bolts. Tighten the bolts to 8 Nm (75 inch lbs.). 9. Secure the power steering hoses into the clip on the lower fan shroud. 10. Install the windshield washer reservoir tank and connect the hose and electrical connector. 11. Install coolant reserve/overflow container hose(s) to radiator filler neck and secure properly with clamps. 12. Install coolant reserve/overflow container or degas container to fan shroud and tighten the bolts to 8 Nm (75 inch lbs.). 13. Connect upper radiator hose and install clamp. 14. Install battery negative cable. 15. Fill cooling system with coolant. 16. Operate the engine until it reaches normal operating temperature. Check cooling system fluid levels. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation CAP-RADIATOR PRESSURE DESCRIPTION All cooling systems are equipped with a pressure cap. For all engines, the pressure cap is located on top of the radiator outlet tank. The cap releases pressure at some point within a range of 97-to-124 kPa (14-to-18 psi). The pressure relief point (in pounds) is engraved on top of the cap The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve. This valve opens when system pressure reaches the release range of 97-to-124 kPa (14-to-18 psi). A rubber gasket seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. OPERATION A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in the cooling system. This causes the vacuum valve to open and coolant in the reserve/overflow container to be drawn through the recovery hose connecting the filler neck and reserve/ overflow container. If the vacuum valve is stuck shut, or the recovery hose is kinked, radiator hoses will collapse on cool down. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap-to-Filler Neck Seal Radiator Cap: Testing and Inspection Radiator Cap-to-Filler Neck Seal RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from the radiator filler neck tube. Attach the hose of the pressure tester tool 7700 (or equivalent) to the tube. It will be necessary to disconnect hose from its adapter for the filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69 to 124 kPa (10 to 18 psi) and hold pressure at a minimum of 55 kPa (8 psi). WARNING: THE WARNING WORDS, DO NOT OPEN HOT, ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove the radiator cap at any time except for the following purposes: ^ Check and adjust antifreeze freeze point. ^ Refill the system with new antifreeze. ^ Conducting service procedures. ^ Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE. PLACE A RAG OVER CAP AND WITHOUT PUSHING CAP DOWN, ROTATE IT COUNTER-CLOCKWISE TO FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH THE COOLANT RESERVE/OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE HAS BEEN RELEASED. WHEN COOLANT AND STEAM STOP BEING PUSHED INTO TANK AND SYSTEM PRESSURE DROPS, REMOVE RADIATOR CAP COMPLETELY. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap-to-Filler Neck Seal > Page 2058 Radiator Cap: Testing and Inspection Radiator Cap RADIATOR CAP Remove the cap from the radiator. Be sure that the sealing surfaces are clean. Moisten the rubber gasket with water and install the cap on the pressure tester 7700 or an equivalent. Operate the tester pump to bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace the cap. Refer to the following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on the radiator. If so, inspect the radiator filler neck and radiator cap's top gasket for damage. Also inspect for dirt or distortion that may prevent the cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 2059 Radiator Cap: Service and Repair RADIATOR CAP CLEANING Use only a mild soap and water to clean the radiator cap. Using any type of solvent may cause damage to the seal in the radiator cap. INSPECTION Hold cap at eye level, right side up. The vent valve at bottom of cap should closed. A slight downward pull on the vent valve should open it. If the rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2065 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2066 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines except SRT10. On SRT10 models, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 260° F in all other markets. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. On all vehicles except SRT10 the engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale. On SRT10 the gauge graphics are black against silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM or ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Closed below ....................................................................................................................................... ............................................................. 195°F (90°C) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Description Thermostat: Description and Operation Description THERMOSTAT-ENGINE COOLANT DESCRIPTION GAS ENGINE CAUTION: Do not operate the engine without a thermostat, except for servicing or testing. The 3.7L/4.7L/5.7L engines use a pellet-type thermostat that controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. The 8.3L engine uses a movable sleeve type thermostat. On all engines the thermostat is closed below 195°F (90°C). Above this temperature, coolant is allowed to flow to the radiator. This provides quick engine warm up and overall temperature control. Coolant leakage into the pellet container will cause the thermostat to fail in the open position. Thermostats very rarely stick. Do not attempt to free a thermostat with a prying device. On the 3.7L/4.7L engine the thermostat is designed to block the flow of the coolant bypass journal by 50% instead of completely blocking the flow. This design controls coolant temperature more accurately Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Description > Page 2075 The same thermostat is used for winter and summer seasons. An engine should not be operated without a thermostat, except for servicing or testing. Operating without a thermostat causes other problems. These are: longer engine warm-up time, unreliable warm-up performance, increased exhaust emissions and crankcase condensation. This condensation can result in sludge formation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Description > Page 2076 Thermostat: Description and Operation Operation OPERATION 3.7L/4.7L/5.7L ENGINE The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open. 8.3L ENGINE The thermostat's primary purpose is to maintain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions. The thermostat is unique because the center does not open and close like a conventional thermostat; it works like a sliding sleeve. The outside sleeve moves, directing coolant flow through the engine block or through the bypass passages back to the water pump. During warm-up below 85°C (185°F), the thermostat is seated in the retracted position. This will allow the coolant to flow into the bypass passage, and back to the water pump. At 85°C (185°F) the thermostat begins to open, allowing coolant to flow through both the bypass and the radiator. At 97°C (207°F) the thermostat will fully open, blocking the path to the bypass, allowing all coolant to flow through the radiator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2077 Thermostat: Testing and Inspection THERMOSTAT ON-BOARD DIAGNOSTICS - GAS ENGINES All gasoline powered models are equipped with On-Board Diagnostics for certain cooling system components. If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. The DTC can also be accessed through the DRBIII scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2078 Thermostat: Service and Repair THERMOSTAT-ENGINE COOLANT REMOVAL 5.7L ENGINE WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE COOLING SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type. 1. Disconnect the negative battery cable. 2. Drain the cooling system 3. Remove the radiator hose clamp (3) and radiator hose (4) at the thermostat housing (2). 4. Remove the thermostat housing mounting bolts, thermostat housing and thermostat. INSTALLATION 1. Position the thermostat and housing (2) on the front cover. 2. Install thermostat housing bolts (1). Tighten the bolts (1) to 13 Nm (112 inch lbs.). 3. Install the radiator hose (4) onto the thermostat housing (2). 4. Fill the cooling system. 5. Connect negative battery cable. 6. Start and warm the engine. Check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump to Timing Chain Case Cover-Bolts .................................................................................................................................. 28 Nm (250 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2082 Water Pump: Description and Operation PUMP-WATER DESCRIPTION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven from the engine crankshaft by a single serpentine drive belt. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The housing has two small holes to allow seepage to escape. The water pump seals are lubricated by the antifreeze in the coolant mixture. No additional lubrication is necessary OPERATION A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2083 Water Pump: Testing and Inspection WATER PUMP A quick test to determine if pump is working is to check if heater warms properly. A defective water pump will not be able to circulate heated coolant through the long heater hose to the heater core. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2084 Water Pump: Service and Repair WATER PUMP REMOVAL 5.7L ENGINE 1. Disconnect negative battery cable. 2. Drain coolant. 3. Remove serpentine belt. 4. Remove fan clutch assembly. 5. Remove coolant fill bottle. 6. Disconnect washer bottle wiring and hose. 7. Remove fan shroud assembly. 8. Remove A/C compressor and generator brace. 9. Remove idler pulleys. 10. Remove belt tensioner assembly. 11. Remove upper and lower radiator hoses. 12. Remove heater hoses. 13. Remove water pump mounting bolts and remove pump. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2085 1. Install water pump and mounting bolts. Tighten mounting bolts to 24 Nm (18 ft. lbs.). 2. Install heater hoses. 3. Install upper and lower radiator hoses. 4. Install belt tensioner assembly 5. Install idler pulleys. 6. Install A/C compressor and alternator brace. Tighten bolt and nuts to 28 Nm (21 ft. lbs.). 7. Install fan shroud assembly. 8. Connect washer bottle wiring and hose. 9. Install coolant fill bottle. 10. Install fan clutch assembly. 11. Install serpentine belt. 12. Connect negative battery cable. 13. Fill coolant. 14. Pressure test coolant system Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CONVERTER - CATALYTIC DESCRIPTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter. OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2090 Catalytic Converter: Service and Repair CONVERTER - CATALYTIC 5.7L ENGINE 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove clamps and nuts (4). 5. Remove catalytic converter to exhaust manifold bolts (2) and nuts (1). 6. Remove catalytic converter assembly (3). INSTALLATION 5.7L ENGINE 1. Install catalytic converter to exhaust clamp (4) on catalytic converter (3) and position into exhaust pipe (5). 2. Make sure the alignment tang on catalytic converter (3) is fully seated in the notch on the exhaust pipe (5). 3. Install catalytic converter to exhaust manifold bolts (2) and nuts (1). 4. Tighten catalytic converter to exhaust manifold bolts (2) to 31 Nm (23 ft. lbs.). 5. Tighten catalytic converter to exhaust pipe clamp nuts (4) to 52.2 Nm (40 ft. lbs.) torque. 6. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold to Cylinder Head ..................................................................................................................................................... 25 Nm (220 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2094 Exhaust Manifold: Description and Operation MANIFOLD - EXHAUST DESCRIPTION The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold. OPERATION The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2095 Exhaust Manifold: Service and Repair EXHAUST MANIFOLD REMOVAL 1. Disconnect negative battery cable. 2. Raise vehicle. 3. Remove exhaust pipe to manifold bolts. 4. Lower vehicle. 5. Install engine support fixture special tool #8534. 6. Raise engine enough to remove manifolds. CAUTION: Do not damage engine harness while raising the engine. 7. Remove heat shield. 8. Remove manifold bolts using sequence provided. 9. Remove manifold and gasket. CLEANING Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air. INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2096 1. Install manifold gasket and manifold. 2. Install manifold bolts and tighten using sequence provided to 25 Nm (18 ft. lbs.). 3. Install heat shield and tighten nuts to 15 Nm (11 ft. lbs.). 4. Lower engine. CAUTION: Do not damage engine harness while lowering the engine. 5. Remove engine support fixture from engine. 6. Raise vehicle. 7. Tighten right and left side engine mount through bolts. 8. Install exhaust flange to pipe bolts. 9. Lower vehicle. 10. Connect negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe Exhaust Pipe: Service and Repair Exhaust Pipe PIPE EXHAUST REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Remove exhaust pipe to manifold bolts, retainers and nuts. 4. Remove the clamp nuts. 5. Remove the exhaust pipe. INSTALLATION 1. Position the exhaust pipe for proper clearance with the frame and underbody parts. A minimum clearance of 25.4 mm (1.0 inch) is required. 2. Position the exhaust pipe to manifold. Install the bolts, retainers and nuts. Tighten the nuts to 31 Nm (23 ft. lbs.) torque. 3. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 4. Lower the vehicle. 5. Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Pipe > Page 2101 Exhaust Pipe: Service and Repair Tailpipe TAILPIPE REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect the exhaust tailpipe support hanger. 4. Remove clamps and nuts. 5. Remove the exhaust tailpipe. INSTALLATION 1. Loosely assemble exhaust tailpipe to permit proper alignment of all parts. 2. Connect the support hangers. 3. Position the exhaust tailpipe for proper clearance with the underbody parts. 4. Tighten all clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 5. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 6. Lower the vehicle. 7. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation Heat Shield: Description and Operation HEAT SHIELDS DESCRIPTION There are two types of heat shields used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system to prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 2105 Heat Shield: Service and Repair HEAT SHIELDS REMOVAL 1. Raise and support the vehicle. 2. Remove the nuts or bolts holding the exhaust heat shield to the floor pan, crossmember or bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 2106 3. Slide the shield out around the exhaust system. INSTALLATION 1. Position the exhaust heat shield to the floor pan, crossmember or bracket and install the nuts or bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Page 2107 2. Tighten the nuts and bolts 11 Nm (100 inch lbs.). 3. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair MUFFLER REMOVAL 3.7L/4.7L/5.7L ENGINE 1. Raise and support the vehicle. 2. Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect the muffler hangers. 4. Remove clamps and nuts. 5. Remove the muffler. INSTALLATION 1. Assemble muffler and clamps loosely to permit proper alignment of all parts. 2. Connect the muffler hangers. 3. Tighten the clamp nuts to 54.2 Nm (40 ft. lbs.) torque. 4. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 5. Lower the vehicle. 6. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: Customer Interest Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2122 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2123 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2124 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: All Technical Service Bulletins Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2130 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2131 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2132 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 2138 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 2139 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 2145 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 2146 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: Customer Interest Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2157 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2158 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2159 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2160 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: All Technical Service Bulletins Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2166 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2167 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2168 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2169 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2174 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2175 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2176 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2182 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2183 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2184 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2185 Engine Control Module: Locations Right Rear Engine Compartment - NGC Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2186 Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2189 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2190 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2191 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2192 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2193 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2194 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2195 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2196 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2197 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2198 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2199 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2200 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2201 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2202 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2203 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2204 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2205 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2206 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2207 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2208 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2209 Engine Control Module: Connector Views Module - Powertrain Control C1 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2210 Module - Powertrain Control C2 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2211 Module - Powertrain Control C3 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2212 Module - Powertrain Control C4 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2213 Engine Control Module: Description and Operation The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2214 engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2215 - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2216 by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2217 - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming Engine Control Module: Service and Repair PCM/ECM/SKREEM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (such as relays and solenoids) and shorted circuits (such as pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE PCM/ECM/SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, the GateWay module (on SRT10 vehicles with a hybrid bus only) and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM Replaced, ECM Replaced, WCM Replaced, or GateWay Replaced under Miscellaneous Functions for the WCM/Wireless Control Module menu item as appropriate. NOTE: - Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. - If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. - Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for Program Ignition Keys or Key FOBs under Miscellaneous Functions for the WCM/Wireless Control Module menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 2220 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 2221 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2225 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2226 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2227 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Oxygen Sensor Relay > Component Information > Description and Operation Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2237 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2238 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2242 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2243 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2244 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2245 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2246 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2247 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2248 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2249 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2250 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2251 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2252 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2253 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2254 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2255 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2256 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 2257 Fuel Pump Relay: Description and Operation A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2261 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2262 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2263 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The 5.7L is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches to the spark plugs. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Ignition Coils - 2 Knock Sensors - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2277 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2278 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2279 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2280 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2284 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2285 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2286 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2290 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2291 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2292 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2293 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL POSITION 1. Disconnect switch 2wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed-Continuity - Pedal Released-No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2300 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2301 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2306 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2307 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2308 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2309 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2310 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit Fuel Level Sensor: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit > Page 2315 Fuel Level Sensor: Locations Fuel Pump Module The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2316 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2317 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 2322 Intake Air Temperature Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 2323 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2324 Sensor - Intake Air Temperature (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2325 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5 volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2326 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2327 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2331 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2332 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2333 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2334 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2335 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2340 Manifold Pressure/Vacuum Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2341 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2342 Sensor - Map (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2343 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2344 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2345 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counterclockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2346 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2354 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2355 Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2356 Oxygen Sensor: Diagrams Sensor-Oxygen - Left Front (3.7L/5.7L) Sensor-Oxygen - Left Rear (3.7L/5.7L LD) Sensor-Oxygen - Left Rear (4.7L/5.7L HD) Sensor-Oxygen - Right Front (3.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2357 Sensor-Oxygen - Right Rear (3.7L/5.7L LD) Sensor-Oxygen - Right Rear (4.7L/5.7L HD) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2358 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2359 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2360 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2364 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2365 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2366 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 2370 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 2375 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 2376 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 2377 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2380 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2381 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2382 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2387 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2388 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2389 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2390 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2391 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2392 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2393 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2394 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2395 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2396 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2397 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2398 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2399 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2400 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2401 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2402 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2403 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2404 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2405 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2406 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2412 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2413 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2414 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2415 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 2419 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2424 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2425 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2426 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 2427 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2432 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2433 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2434 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2435 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 2436 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 2441 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2445 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2446 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2447 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2448 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2449 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2454 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2455 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > Page 2459 Idle Speed: Description and Operation 5.7L: A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Fig. 1 AIR CLEANER COVER Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2464 Fig. 2 AIR CLEANER HOUSING 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips (5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4 Nm (40 inch lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 2465 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2474 right front side of the engine block (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2475 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2476 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2477 Firing Order ......................................................................................................................................... ......................................................... 1-8-4-3-6-5-7-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plugs Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 2486 Spark Plug: Mechanical Specifications Gap ...................................................................................................................................................... ................................................... 0.045 in. (1.14mm) Torque ................................................................................................................................................. ................................................... 13 ft. lbs. (18 N-m) Torque critical design. Do not exceed 15 ft. lbs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2487 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2488 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L engines. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. This is especially true when plugs are equipped with tapered seats. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation REMOVAL Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary. 5. Inspect spark plug condition. INSTALLATION NOTE: The 4.7L is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 27 N.m (20 ft.lbs.). 3.7L & 4.7L. 3. The 5.7L is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. torque. Tighten spark plugs to 18 N.m (13 ft.lbs). NOTE: 5.7L does not use an O-ring 4. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 5. Install ignition coil(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 2491 Spark Plug: Service and Repair Cleaning CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2495 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Disable the fuel system. 4. Remove the ASD relay. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2501 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2502 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2503 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2504 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 2509 Intake Air Temperature Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 2510 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2511 Sensor - Intake Air Temperature (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2512 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5 volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2513 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2514 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2518 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2519 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2520 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: Customer Interest Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2529 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2530 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2531 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: All Technical Service Bulletins Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2537 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2538 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2539 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings Outside Temperature Display: All Technical Service Bulletins Instruments - Incorrect Outside Temperature Readings NUMBER: 08-026-06 REV. A GROUP: Electrical DATE: October 25, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-026-06, DATED JUNE 02, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Overhead Console Temperature Reading Inaccurate Or Dome Lamp Turns Off Too Soon OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node (CCN) with new software. MODELS: 2006 (DRIDHID1) Ram Truck NOTE: This bulletin applies to vehicles built on or before May 30, 2006 (MDH 0530XX). SYMPTOM/CONDITION: The vehicle operator may notice that if a vehicle door is left open for longer than 20 seconds the illuminated interior (dome) lamps will turn off. The vehicle operator may describe that the ambient temperature first displayed in the overhead console is not accurate (displays -40°C or -40°F), when the ignition switch is turned to the "On" position, then slowly updates to the outside ambient temperature as the vehicle is driven. NOTE: DO NOT reprogram the CCN if the overhead displayed temperature stays at the -40°C (-40°F) reading after driving the vehicle for MORE THAN 3 minutes and at speeds greater than 32 Km/h (20 mph). Check the system for an open circuit condition. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 2545 REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash CCN" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the appropriate calibration then select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the CCN update is complete, select "OK". I. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 2546 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 2552 REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash CCN" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the appropriate calibration then select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the CCN update is complete, select "OK". I. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 2553 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2559 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2560 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2561 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2562 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL POSITION 1. Disconnect switch 2wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed-Continuity - Pedal Released-No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2569 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2570 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2575 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2576 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2577 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2578 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2579 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2585 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2586 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2587 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2588 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2589 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2590 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2591 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2592 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2593 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2594 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2595 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2596 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2597 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2598 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2599 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2600 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2601 Data Link Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2602 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2603 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2604 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 2605 Data Link Connector Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 2606 Data Link Connector: Description and Operation The Data Link Connector (DLC) (3) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the stamped metal lower instrument panel reinforcement (2), just below the lower edge of the instrument panel steering column opening cover (1). The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. The DLC on SRT10 models also includes a Programmable Communications Interface (PCI or J1850) bus link for diagnosis of the GateWay Module and a Serial Communications Interface (SCI) bus link for diagnosis of the Powertrain Control Module (PCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation Electronic Throttle Control Indicator: Description and Operation An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional 5.7 liter gasoline engine, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system is ineffective or inoperative. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is illuminated for about six seconds. The entire bulb test is a function of the PCM. - ETC Lamp-On Message - Each time the cluster receives a lamp-on message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about twelve seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator will be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no ETC lamp messages for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected an ETC system malfunction and/or that the ETC system is inoperative. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, the instrument cluster and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ETC indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: Customer Interest Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2618 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2619 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2620 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2621 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: All Technical Service Bulletins Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2627 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2628 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2629 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2630 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2635 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2636 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2637 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2643 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2644 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2645 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2646 Engine Control Module: Locations Right Rear Engine Compartment - NGC Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2647 Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2667 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2668 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2669 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2670 Engine Control Module: Connector Views Module - Powertrain Control C1 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2671 Module - Powertrain Control C2 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2672 Module - Powertrain Control C3 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2673 Module - Powertrain Control C4 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2674 Engine Control Module: Description and Operation The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2675 engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2676 - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2677 by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2678 - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming Engine Control Module: Service and Repair PCM/ECM/SKREEM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (such as relays and solenoids) and shorted circuits (such as pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE PCM/ECM/SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, the GateWay module (on SRT10 vehicles with a hybrid bus only) and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM Replaced, ECM Replaced, WCM Replaced, or GateWay Replaced under Miscellaneous Functions for the WCM/Wireless Control Module menu item as appropriate. NOTE: - Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. - If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. - Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for Program Ignition Keys or Key FOBs under Miscellaneous Functions for the WCM/Wireless Control Module menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 2681 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 2682 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit Fuel Level Sensor: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit > Page 2687 Fuel Level Sensor: Locations Fuel Pump Module The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2688 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2689 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation 5.7L: A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 2693 Idle Speed/Throttle Actuator - Electronic: Service and Repair The IAC motor is not serviceable on the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2698 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2699 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2700 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2701 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2702 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2703 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2704 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2705 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2706 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2707 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2708 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2709 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2710 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2711 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2712 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2713 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2714 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2715 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2716 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2717 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2718 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2719 8w-18-3 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2720 8w-18-4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2721 8w-18-5 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2722 8w-18-6 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 2723 8w-18-7 (SRT) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2724 Information Bus: Description and Operation The primary on-board communication network between microprocessor-based electronic control modules in this vehicle is the Controller Area Network (CAN) data bus system. However, on SRT10 vehicles the Powertrain Control Module (PCM) uses the DaimlerChrysler Programmable Communication Interface (PCI) data bus system in combination with the CAN bus to form a hybrid bus system. A data bus network minimizes redundant wiring connections; and, at the same time, reduces wire harness complexity, sensor current loads and controller hardware by allowing each sensing device to be connected to only one module (also referred to as a node). Each node reads, then broadcasts its sensor data over the bus for use by all other nodes requiring that data. Each node ignores the messages on the bus that it cannot use. The CAN bus is a two-wire multiplex system, while the PCI bus is a single-wire multiplex system. Multiplexing is any system that enables the transmission of multiple messages over a single channel or circuit. The CAN bus is used for communication between all vehicle nodes, except on the SRT10 where the PCM uses the PCI bus. In addition, certain vehicles may also be equipped with a Serial Controller Interface (SCI) or a K-Line serial link bus to provide direct diagnostic access between a diagnostic scan tool connected to the industry-standard 16-way Data Link Connector (DLC) located below the driver side instrument panel and certain powertrain nodes. There are actually three separate CAN bus systems used in the vehicle. They are designated: the CAN-B, the CAN-C and the Diagnostic CAN-C. The CAN-B and CAN-C systems provide on-board communication between all nodes in the vehicle. The CAN-C is the faster of the two systems providing near real-time communication (500 Kbps), but is less fault tolerant than the CAN-B system. The CAN-C is used exclusively for communications between critical powertrain and chassis nodes. The slower (83.3 Kbps), but more fault tolerant CAN-B system is used for communications between body and interior nodes. The CAN-B fault tolerance comes from its ability to revert to a single wire communication mode if there is a problem in the bus wiring. The added speed of the CAN data bus is many times faster than previous data bus systems. This added speed facilitates the addition of more electronic control modules or nodes and the incorporation of many new electrical and electronic features in the vehicle. The Diagnostic CAN-C bus is also capable of 500 Kbps communication, and is sometimes informally referred to as the CAN-D system to differentiate it from the other high speed CAN-C bus. The Diagnostic CAN-C is used exclusively for the transmission of diagnostic information between the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) and a diagnostic scan tool connected to the DLC. All vehicles have a central CAN gateway or hub module integral to the TIPM that is connected to all three CAN buses. The TIPM is located in the engine compartment near the battery. This gateway physically and electrically isolates the CAN buses from each other and coordinates the bi-directional transfer of messages between them. On SRT10 vehicles a separate, dedicated gateway module secured to the back of the battery tray on the right side of the engine compartment coordinates the bi-directional transfer of messages between the PCI bus line from the PCM and the CAN bus connected to all of the other nodes in the vehicle. Either the Controller Area Network (CAN) data bus or the hybrid bus system that integrates the Programmable Communications Interface (PCI) data bus with the CAN bus allows all electronic modules or nodes connected to the bus to share information with each other. Regardless of whether a message originates from a module on the low speed PCI or CAN-B bus or on the high speed CAN-C or CAN-D bus, the message structure and layout is similar, which allows the Totally Integrated Power Module/Central GateWay (TIPM or TIPMCGW) to process and transfer messages between the buses. The TIPM also stores a Diagnostic Trouble Code (DTC) for certain bus network faults. All modules (also referred to as nodes) transmit and receive messages over one of these buses, either the singlewire PCI bus or the two-wire CAN bus. Data exchange between nodes is achieved by serial transmission of encoded data messages. Each node can both send and receive serial data simultaneously. Bus messages are carried over the data bus in the form of Variable Pulse Width Modulated (VPWM) signals which, when the high and low voltage pulses are strung together, form a message. Each node uses arbitration to sort the message priority if two competing messages are attempting to be broadcast at the same time. The voltage network used to transmit messages requires biasing and termination. Each module on the bus network provides its own biasing and termination. Each node terminates the bus through a terminating resistor and a terminating capacitor. There are two types of nodes on the bus. The dominant node terminates the bus through a 1 KW resistor and a 3,300 pF capacitor, typically resulting in about a 3,300 ohm termination resistance. However, this resistance value may vary somewhat by application. The TIPM (or TIPMCGW) is the only dominant node in this network. A non-dominant (or recessive) node terminates the bus through an 11 KW resistor and a 330 pF capacitor, typically resulting in about a 10,800 ohm termination resistance. PROGRAMMABLE COMMUNICATIONS INTERFACE DATA BUS The PCI (or J1850) data bus communication protocol exceeds the Society of Automotive Engineers (SAE) J1850 Standard for Class B Multiplexing. The PCI data bus speed is an average 10.4 Kilobits per second (Kbps). CONTROLLER AREA NETWORK DATA BUS The communication protocol being used for the CAN data bus is a non-proprietary, open standard adopted from the Bosch CAN Specification 2.0b. The CAN is the faster of the two primary buses in the hybrid bus system, with the CAN-C bus providing near real-time communication (500 Kbps). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 2725 The CAN bus nodes are connected in parallel to the two-wire bus using a twisted pair, where the wires are wrapped around each other to provide shielding from unwanted electromagnetic induction, thus preventing interference with the relatively low voltage signals being carried through them. The twisted pairs have between 33 and 50 twists per meter (yard). While the CAN bus is operating (active), one of the bus wires will carry a higher voltage and is referred to as the CAN High or CAN bus (+) wire, while the other bus wire will carry a lower voltage and is referred to as the CAN Low or CAN bus (-) wire. Refer to the CAN Bus Voltages table. In order to minimize the potential effects of Ignition-Off Draw (IOD), the CAN-B network employs a sleep strategy. However, a network sleep strategy should not be confused with the sleep strategy of the individual nodes on that network, as they may differ. For example: The CAN-C bus network is awake only when the ignition switch is in the On or Start positions; however, the TIPM, which is on the CAN-C bus, may still be awake with the ignition switch in the Accessory or Unlock positions. The integrated circuitry of an individual node may be capable of processing certain sensor inputs and outputs without the need to utilize network resources. The CAN-B bus network remains active until all nodes on that network are ready for sleep. This is determined by the network using tokens in a manner similar to polling. When the last node that is active on the network is ready for sleep, and it has already received a token indicating that all other nodes on the bus are ready for sleep, it broadcasts a bus sleep acknowledgment message that causes the network to sleep. Once the CAN-B bus network is asleep, any node on the bus can awaken it by transmitting a message on the network. The TIPM will keep either the CAN-B or the CAN-C bus awake for a timed interval after it receives a diagnostic message for that bus over the Diagnostic CAN-C bus. In the CAN system, available options are configured into the TIPM at the assembly plant, but additional options can be added in the field using the diagnostic scan tool. The configuration settings are stored in non-volatile memory. The TIPM also has two 64-bit registers, which track each of the as-built and currently responding nodes on the CAN-B and CAN-C buses. The TIPM stores a Diagnostic Trouble Code (DTC) in one of two caches for any detected active or stored faults in the order in which they occur. One cache stores powertrain (P-Code), chassis (C-Code) and body (B-Code) DTCs, while the second cache is dedicated to storing network (U-Code) DTCs. If there are intermittent or active faults in the CAN network, a diagnostic scan tool connected to the Diagnostic CAN-C bus through the 16-way Data Link Connector (DLC) may only be able to communicate with the TIPM. To aid in CAN network diagnosis, the TIPM will provide CAN-B and CAN-C network status information to the scan tool using certain diagnostic signals. In addition, the transceiver in each node on the CAN-C bus will identify a bus off hardware failure , while the transceiver in each node on the CAN-B bus will identify a general bus hardware failure. The transceivers for some CAN-B nodes will also identify certain failures for both CAN-B bus signal wires. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2729 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2730 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2731 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2732 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2733 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2737 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2738 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2739 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC s, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC s may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2747 Manifold Pressure/Vacuum Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2748 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2749 Sensor - Map (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2750 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2751 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2752 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counterclockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2753 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2761 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2762 Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2763 Oxygen Sensor: Diagrams Sensor-Oxygen - Left Front (3.7L/5.7L) Sensor-Oxygen - Left Rear (3.7L/5.7L LD) Sensor-Oxygen - Left Rear (4.7L/5.7L HD) Sensor-Oxygen - Right Front (3.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2764 Sensor-Oxygen - Right Rear (3.7L/5.7L LD) Sensor-Oxygen - Right Rear (4.7L/5.7L HD) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2765 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2766 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2767 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor Relay > Component Information > Description and Operation Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2774 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2775 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2776 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: Customer Interest Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2786 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2787 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2788 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: All Technical Service Bulletins Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2794 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2795 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 2796 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: Customer Interest Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2807 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2808 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2809 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2810 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 Engine Control Module: All Technical Service Bulletins Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2816 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2817 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2818 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 2819 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2824 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2825 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2826 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure Engine Control Module: All Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2832 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2833 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 08-030-06A > Aug > 06 > Engine Control - PCM Initialization Procedure > Page 2834 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2835 Engine Control Module: Locations Right Rear Engine Compartment - NGC Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2836 Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2839 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2840 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2841 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2842 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2854 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2855 Engine Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2856 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Engine Control Module: Connector Views Module - Powertrain Control C1 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Module - Powertrain Control C2 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Module - Powertrain Control C3 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Module - Powertrain Control C4 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2863 Engine Control Module: Description and Operation The Powertrain Control Module (PCM) is located in the right-rear section of the engine compartment under the cowl. Two different PCM's are used (JTEC and NGC). These can be easily identified. JTEC's use three 32-way connectors, NGC's use four 38-way connectors MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. For example, the PCM must calculate different injector pulse width and ignition timing for idle than it does for wide open throttle (WOT). The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2864 engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD or O2S heater relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2865 - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the A/C compressor clutch relay. This is done if A/C has been selected by the vehicle operator and specified pressures are met at the high and low-pressure A/C switches. Refer to Heating and Air Conditioning. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2866 by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil(s) on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors SENSOR RETURN The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. Refer to Power Grounds for more information. The PCM operates the fuel system. The PCM is a pre-programmed, triple microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed, power steering pump pressure, and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - ABS module (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - A/C pressure transducer - Auto shutdown (ASD) sense - Battery temperature sensor - Battery voltage - Brake switch - J1850 bus (+) circuits - J1850 bus (-) circuits - Camshaft position sensor signal - Crankshaft position sensor - Data link connection for a scan tool - EATX module (if equipped) - Engine coolant temperature sensor - Fuel level (through J1850 circuitry) - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 2867 - Knock sensors (2 on 3.7L engine) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transfer case switch (4WD range position) - Vehicle speed signal NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - J1850 bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for DRB scan tool - EGR valve control solenoid (if equipped) - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Idle air control (IAC) motor - Ignition coil(s) - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through J1850 circuits. - Oxygen sensor heater relays - Oxygen sensors (pulse width modulated) - Radiator cooling fan relay (pulse width modulated) - Speed control vacuum solenoid - Speed control vent solenoid - Tachometer (if equipped). Driven through J1850 circuits. - Transmission convertor clutch circuit. Driven through J1850 circuits. 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (certain automatic transmissions). IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming Engine Control Module: Service and Repair PCM/ECM/SKREEM Programming NOTE: Before replacing the Powertrain Control Module (PCM) or Engine Control Module (ECM), be certain to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM/ECM driver/control circuit failures are caused by internal component failures (such as relays and solenoids) and shorted circuits (such as pull-ups, drivers, and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has been set. When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key REmote Entry Module (SKREEM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: 1. Program the new PCM/ECM. 2. Program the new SKREEM (also sometimes referred to as the Wireless Control Module or WCM). 3. Replace all ignition keys and program them into the new SKREEM/WCM. PROGRAMMING THE PCM/ECM/SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, the GateWay module (on SRT10 vehicles with a hybrid bus only) and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new modules using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM Replaced, ECM Replaced, WCM Replaced, or GateWay Replaced under Miscellaneous Functions for the WCM/Wireless Control Module menu item as appropriate. NOTE: - Be certain to enter the correct country code for the SKREEM/WCM. If the incorrect country code is programmed into the SKREEM, it cannot be changed and the SKREEM must be replaced. - If the PCM/ECM and the SKREEM/WCM are replaced at the same time, all vehicle ignition keys will need to be replaced and the new keys programmed into the new SKREEM/WCM. - Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary). PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for Program Ignition Keys or Key FOBs under Miscellaneous Functions for the WCM/Wireless Control Module menu item. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - Programming Not Attempted - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - Programming Key Failed (Possible Used Key From Wrong Vehicle) - SKREEM is unable to program an ignition key transponder due to one of the following: The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 Keys Already Learned, Programming Not Done - The SKREEM transponder ID memory is full. - Learned Key In Ignition - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 2870 Engine Control Module: Service and Repair Module - Powertrain Control CAUTION: - Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using a scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. - Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. REMOVAL The PCM (1) is located in the engine compartment attached to the dash panel (3). To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect negative battery cable at battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/ECM/SKREEM Programming > Page 2871 2. Remove cover over electrical connectors. Cover snaps onto PCM. 3. Carefully unplug the three 32-way connectors (four 38-way connectors if equipped with NGC) from PCM (1). 4. Remove three PCM mounting bolts (4) and remove PCM from vehicle. INSTALLATION 1. Install PCM (3) and 3 mounting bolts (4) to vehicle. 2. Tighten bolts. Refer to torque specifications. 3. Check pin connectors in the PCM and the three 32-way connectors (four 38-way connectors if equipped with NGC) for corrosion or damage. Also, the pin heights in connectors should all be same. Repair as necessary before installing connectors. 4. Install three 32-way connectors (four 38-way connectors if equipped with NGC). 5. Install cover over electrical connectors. Cover snaps onto PCM. 6. Install negative battery cable. 7. The 5.7L V-8 engine is equipped with a fully electronic accelerator pedal position sensor. If equipped with a 5.7L, also perform the following 3 steps: a. Connect negative battery cable to battery. b. Turn ignition switch ON, but do not crank engine. c. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn electrical parameters. d. The scan tool may also be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 8. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 9. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTC's) from PCM. Also use the scan tool to reprogram new PCM with vehicles original Vehicle Identification Number (VIN) and original vehicle mileage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2875 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2876 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 2877 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Oxygen Sensor Relay > Component Information > Description and Operation Oxygen Sensor Relay: Description and Operation DESCRIPTION The Oxygen Sensors (02S) are attached to, and protrude into the vehicle exhaust system Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors Federal Emission Packages Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2) With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor The downstream sensor (1/2) is located just after the main catalytic convertor California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as ill and 2/1) and 2 downstream (referred to as 1/2 and 2/2) With this emission pack-age, the right upstream sensor (2/i) is located in the right exhaust downpipe just before the mini-catalytic convertor The left upstream sensor (1/i) is located in the left exhaust downpipe just before the mini-catalytic convertor The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 2886 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2887 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2888 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 2889 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2893 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2894 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 2895 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2899 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2900 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2901 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2902 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection SWITCH CLUTCH PEDAL POSITION 1. Disconnect switch 2wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed-Continuity - Pedal Released-No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation Coolant Temperature Sensor/Switch (For Computer): Description and Operation SENSOR-ENGINE COOLANT TEMPERATURE DESCRIPTION The Engine Coolant Temperature (ECT) sensor is used to sense engine coolant temperature. The sensor protrudes into an engine water jacket. The ECT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as engine coolant temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. OPERATION At key-on, the Powertrain Control Module (PCM) sends out a regulated 5 volt signal to the ECT sensor. The PCM then monitors the signal as it passes through the ECT sensor to the sensor ground (sensor return). When the engine is cold, the PCM will operate in Open Loop cycle. It will demand slightly richer air-fuel mixtures and higher idle speeds. This is done until normal operating temperatures are reached. The PCM uses inputs from the ECT sensor for the following calculations: for engine coolant temperature gauge operation through CCD or PCI (J1850) communications - Injector pulse-width - Spark-advance curves - ASD relay shut-down times - Idle Air Control (IAC) motor key-on steps - Pulse-width prime-shot during cranking - O2 sensor closed loop times - Purge solenoid on/off times - Cooling fan control - Temperature gauge operation - A/C cutoff at high coolant temperatures - EGR solenoid on/off times (if equipped) - Leak Detection Pump operation (if equipped) - Radiator fan relay on/off times (if equipped) - Target idle speed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2909 Coolant Temperature Sensor/Switch (For Computer): Service and Repair SENSOR-ENGINE COOLANT TEMPERATURE REMOVAL 5.7L V-8 The Engine Coolant Temperature (ECT) sensor on the 5.7L engine is located under the air conditioning compressor. It is installed into a water jacket at the front of the cylinder block. WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOVING THE COOLANT TEMPERATURE SENSOR. 1. Partially drain the cooling system. 2. Remove accessory drive belt. 3. Carefully unbolt air conditioning compressor from front of engine. Do not disconnect any A/C hoses from compressor. Temporarily support compressor to gain access to ECT sensor. 4. Disconnect electrical connector from sensor. 5. Remove sensor from cylinder block. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Description and Operation > Page 2910 1. Apply thread sealant to sensor threads. 2. Install sensor into engine. 3. Tighten sensor to 11 Nm (8 ft. lbs.) torque. 4. Connect electrical connector to sensor. 5. Carefully bolt air conditioning compressor onto the front of engine. 6. Install accessory drive belt. 7. Replace any lost engine coolant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 2915 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2916 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2917 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2918 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2919 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit Fuel Level Sensor: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Fuel Level Sending Unit > Page 2924 Fuel Level Sensor: Locations Fuel Pump Module The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2925 Fuel Level Sensor: Description and Operation The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). The fuel pump module has 4 different circuits (wires). Two of these circuits are used for the fuel gauge sending unit for fuel gauge operation, and for certain OBD II emission requirements. The other 2 wires are used for electric fuel pump operation. For Fuel Gauge Operation: A constant current source is supplied to the resistor track on the fuel gauge sending unit. This is fed directly from the Powertrain Control Module (PCM). NOTE: For diagnostic purposes, this 12V power source can only be verified with the circuit opened (fuel pump module electrical connector unplugged). With the connectors plugged, output voltages will vary from about 0.6 volts at FULL, to about 8.6 volts at EMPTY (about 8.6 volts at EMPTY for Jeep models, and about 7.0 volts at EMPTY for Dodge Truck models). The resistor track is used to vary the voltage (resistance) depending on fuel tank float level. As fuel level increases, the float and arm move up, which decreases voltage. As fuel level decreases, the float and arm move down, which increases voltage. The varied voltage signal is returned back to the PCM through the sensor return circuit. Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard-wired (not multi-plexed). After the voltage signal is sent from the resistor track, and back to the PCM, the PCM will interpret the resistance (voltage) data and send a message across the multi-plex bus circuits to the instrument panel cluster. Here it is translated into the appropriate fuel gauge level reading. For OBD II Emission Monitor Requirements: The PCM will monitor the voltage output sent from the resistor track on the sending unit to indicate fuel level. The purpose of this feature is to prevent the OBD II system from recording/ setting false misfire and fuel system monitor diagnostic trouble codes. The feature is activated if the fuel level in the tank is less than approximately 15 percent of its rated capacity. If equipped with a Leak Detection Pump (EVAP system monitor), this feature will also be activated if the fuel level in the tank is more than approximately 85 percent of its rated capacity. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2926 Fuel Level Sensor: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations Intake Air Temperature Sensor: Component Locations The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 2931 Intake Air Temperature Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 2932 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2933 Sensor - Intake Air Temperature (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2934 Intake Air Temperature Sensor: Description and Operation The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold (2) with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5 volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2935 Intake Air Temperature Sensor: Service and Repair REMOVAL The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 2936 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. INSTALLATION The intake manifold air temperature (IAT) sensor (2) is installed into the front of the intake manifold air box plenum. 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold. 3. Position sensor into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2940 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2941 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2942 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2943 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2944 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations Manifold Pressure/Vacuum Sensor: Component Locations The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2949 Manifold Pressure/Vacuum Sensor: Connector Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Component Locations > Page 2950 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2951 Sensor - Map (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2952 Manifold Pressure/Vacuum Sensor: Description and Operation The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2953 object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in.Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2954 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL The Manifold Absolute Pressure (MAP) sensor is mounted to the front of the intake manifold air plenum box. 1. Disconnect electrical connector at sensor by sliding release lock out. Press down on lock tab for removal. 2. Rotate sensor (3) 1/4 turn counterclockwise for removal. 3. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2955 The Manifold Absolute Pressure (MAP) sensor (1) is mounted to the front of the intake manifold air plenum box. 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring seal for cuts or tears. 3. Position sensor into manifold. 4. Rotate sensor 1/4 turn clockwise for installation. 5. Connect electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Diagrams Sensor - Engine Oil Pressure (SRT/5.7L A/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2963 Oxygen Sensor: Connector Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 2964 Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2965 Oxygen Sensor: Diagrams Sensor-Oxygen - Left Front (3.7L/5.7L) Sensor-Oxygen - Left Rear (3.7L/5.7L LD) Sensor-Oxygen - Left Rear (4.7L/5.7L HD) Sensor-Oxygen - Right Front (3.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2966 Sensor-Oxygen - Right Rear (3.7L/5.7L LD) Sensor-Oxygen - Right Rear (4.7L/5.7L HD) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2967 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2968 Oxygen Sensor: Description and Operation The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages: Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2969 Oxygen Sensor: Service and Repair REMOVAL CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: THE EXHAUST MANIFOLD, EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. 1. Raise and support vehicle. 2. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting sensor electrical connector, do not pull directly on wire going into sensor. 3. Remove O2S sensor with an oxygen sensor removal and installation tool. 4. Clean threads in exhaust pipe using appropriate tap. INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor. Tighten to 30 N.m (22 ft. lbs.) torque. 2. Connect O2S sensor wire connector. 3. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2973 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2974 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations > Page 2975 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 2979 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 2984 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 2985 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 2986 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2989 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2990 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 2991 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2996 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2997 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2998 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2999 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3000 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3001 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3002 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3003 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3004 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3005 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3006 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3007 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3008 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3009 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3010 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3011 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3012 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3013 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3014 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3015 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page 3019 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3024 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3025 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3026 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3029 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3030 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3031 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams Valve Deactivation Solenoid: Diagrams Solenoid - Multiple Displacement No.1 (5.7L) Solenoid - Multiple Displacement No.4 (5.7L) Solenoid - Multiple Displacement No.6 (5.7L) Solenoid - Multiple Displacement No.7 (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Page 3035 Valve Deactivation Solenoid: Description and Operation SOLENOID-MDS DESCRIPTION The Multi Displacement System selectively deactivates cylinders 1,4,6, and 7, to improve fuel economy. It has two modes of operation: 8 cylinders for acceleration and heavy loads. - 4 cylinders for cruising and city traffic. The main components of the Multi Displacement System are Unique MDS camshaft. - Deactivating roller tappets. - 4 control valves/solenoids. - control valve/solenoid wiring harness. - oil temp sensor. OPERATION Cylinder Deactivation - Trap an exhaust charge from a normal combustion event - Normal combustion event - Don't open the exhaust valve - Don't open the intake valve - Piston is an air spring - Cylinders deactivated in firing sequence Cylinder Reactivation - Open the exhaust valve - Empty the cylinder - Open the intake valve - Normal combustion event - Cylinders reactivated in firing sequence Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Page 3036 Valve Deactivation Solenoid: Testing and Inspection SOLENOID-MDS The Multi Displacement System has the following detectable issues: Solenoid circuit - Fail to deactivate a cylinder(s) - Fail to reactivate a cylinder(s) - Low oil pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Page 3037 Valve Deactivation Solenoid: Service and Repair SOLENOID-MDS REMOVAL 1. Disconnect the negative battery cable. 2. Remove the intake manifold. 3. Remove wiring harness connectors from the MDS solenoids. 4. Remove hold down bolt from MDS solenoid. 5. Remove MDS solenoid. INSTALLATION 1. Verify that MDS bores are free of debris, before solenoid installation. 2. Install MDS solenoid fully into block. 3. Install hold down bolt and torque to 11 Nm (97 inch lbs.). 4. Reconnect the MDS wiring harness to the solenoids. 5. Install the intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3042 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3043 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3044 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3045 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3046 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3047 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3048 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3053 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3054 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3055 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3056 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3057 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3058 Vehicle Speed Sensor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3059 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3060 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3061 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation Catalytic Converter: Description and Operation CONVERTER - CATALYTIC DESCRIPTION WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. THEREFORE, NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER. THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME. CAUTION: DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter. The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core. 50 State emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline catalytic converter. OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3066 Catalytic Converter: Service and Repair CONVERTER - CATALYTIC 5.7L ENGINE 1. Raise and support vehicle. 2. Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. 3. Disconnect oxygen sensor electrical connectors. 4. Remove clamps and nuts (4). 5. Remove catalytic converter to exhaust manifold bolts (2) and nuts (1). 6. Remove catalytic converter assembly (3). INSTALLATION 5.7L ENGINE 1. Install catalytic converter to exhaust clamp (4) on catalytic converter (3) and position into exhaust pipe (5). 2. Make sure the alignment tang on catalytic converter (3) is fully seated in the notch on the exhaust pipe (5). 3. Install catalytic converter to exhaust manifold bolts (2) and nuts (1). 4. Tighten catalytic converter to exhaust manifold bolts (2) to 31 Nm (23 ft. lbs.). 5. Tighten catalytic converter to exhaust pipe clamp nuts (4) to 52.2 Nm (40 ft. lbs.) torque. 6. Check the exhaust system for contact with the body panels. A minimum of 25.4 mm (1.0 inch) is required between the exhaust system components and body/frame parts. Make the necessary adjustments, if needed. 7. Lower the vehicle. 8. Start the engine and inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Canister Purge Solenoid: Component Locations The duty cycle EVAP canister purge solenoid is located in the engine compartment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3072 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3073 Solenoid - EVAP/Purge (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3074 Canister Purge Solenoid: Description and Operation The duty cycle EVAP canister purge solenoid is located in the engine compartment. It is attached to the side of the Power Distribution Center (PDC). The Powertrain Control Module (PCM) operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during open loop operation. The engine enters closed loop operation after it reaches a specified temperature and the time delay ends. During closed loop operation, the PCM energizes and de-energizes the solenoid 5 or 10 times per second, depending upon operating conditions. The PCM varies the vapor flow rate by changing solenoid pulse width. Pulse width is the amount of time the solenoid energizes. The PCM adjusts solenoid pulse width based on engine operating condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3075 Canister Purge Solenoid: Service and Repair REMOVAL The duty cycle EVAP canister purge solenoid (3) is located in the engine compartment. It is attached to the side of the Power Distribution Center (PDC). 1. Disconnect electrical wiring connector at solenoid. 2. Disconnect vacuum harness (2) at solenoid. 3. Remove solenoid from mounting bracket. INSTALLATION 1. Install solenoid assembly to mounting bracket. 2. Connect vacuum harness. 3. Connect electrical connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3084 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3085 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3091 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3092 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations EVAP canisters (5) are located near the front of the fuel tank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3096 Evaporative Emission Control Canister: Description and Operation Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3097 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. The EVAP canisters are filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canisters are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canisters. Fuel vapors are temporarily held in the canisters until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canisters to be purged at predetermined times and at certain engine operating conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3098 Evaporative Emission Control Canister: Service and Repair REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3099 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Type 1 Canisters Use the following procedure for vertically mounted canisters. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3100 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). Remove necessary skid plates. 3. Remove fuel tubes/lines at each EVAP canister. Note location of tubes/lines before removal for easier installation. 4. Remove lower support bracket (4). 5. Remove mounting nuts (1) at top of each canister. 6. Remove each canister from upper support bracket. Type 2 Canisters Use the following procedure for horizontally mounted canisters. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the EVAP canister(s). Remove necessary skid plates. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3101 3. Remove fuel tubes/lines (1) at each EVAP canister. Note location of tubes/lines before removal for easier installation. Remove bolts (6). 4. Remove nut (1) and remove NVLD filter (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3102 5. Remove nuts (4) and remove NVLD filter support bracket (2). Remove upper canister. 6. Remove nuts (5) and remove lower canister (6). Slip lower canister pins (7) from rubber grommets. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3103 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3104 Two EVAP canisters are used. Depending on vehicle model and fuel tank size, the canisters may be mounted either vertically or horizontally. These maintenance free, EVAP canisters (5) are located near the front of the fuel tank. Type 1 Canisters Use the following procedure for vertically mounted canisters. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3105 1. Place each canister (5) and (6) into upper support bracket and install nuts. Refer to Torque Specifications. 2. Install lower support bracket (4). Refer to Torque Specifications. 3. Carefully install vapor/vacuum lines. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD Pump, LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. If necessary, install skid plate(s). Type 2 Canisters Use the following procedure for horizontally mounted canisters. 1. Slip lower canister pins (7) into rubber grommets. Install lower canister (6) and nuts (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3106 2. Install upper canister (1). Install NVLD filter support bracket (2) and install nuts (4). 3. Install NVLD filter (2) and nut (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 3107 4. Carefully install vapor/vacuum lines, and fuel tubes/lines (1) to each EVAP canister. Install bolts (6). 5. The vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the NVLD Pump, LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 6. If necessary, install skid plate(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3116 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3117 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3123 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3124 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Diagrams Assembly - Natural Vacuum Leak Detection (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump Leak Detection Pump: Locations Leak Detection Pump The Leak Detection Pump (LDP) (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump > Page 3132 Leak Detection Pump: Locations Natural Vac Leak Detection Equipped With Horizontally Mounted EVAP Canisters The NVLD pump (4) is attached to the EVAP canister. Equipped With Vertically Mounted EVAP Canisters Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Leak Detection Pump > Page 3133 The NVLD pump (4) is located at the front of fuel tank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump Leak Detection Pump: Description and Operation Leak Detection Pump Vehicles equipped with JTEC engine control modules use a leak detection pump. Vehicles equipped with NGC engine control modules use an NVLD pump. Refer to Natural Vacuum - Leak Detection (NVLD) for additional information. The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel system. Leaks in the system, even small ones, can allow fuel vapors to escape into the atmosphere. Government regulations require onboard testing to make sure that the evaporative (EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and blockage. It also performs self-diagnostics. During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the LDP to seal the vent valve and pump air into the system to pressurize it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to maintain pressure in the system. EVAP LEAK DETECTION SYSTEM COMPONENTS Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to test for leaks in the system. EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of pressure. EVAP Canister: The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge Orifice: Limits purge volume. EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while allowing a vent to atmosphere for the EVAP system. The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP system vent to atmospheric pressure so the system can be pressurized for leak testing. The diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure of about 7.5" H2O (1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air into the EVAP system. This allows detection of leaks and blockage. The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and inlet check valve, and pump it out through an outlet check valve into the EVAP system. The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage) signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and off. LDP AT REST (NOT POWERED) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3136 When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the engine vacuum port and opens the atmospheric pressure port connected through the EVAP system air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric pressure. DIAPHRAGM UPWARD MOVEMENT When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds spring force. This upward movement closes the vent valve. It also causes low pressure below the diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the diaphragm completes its upward movement, the LDP reed switch turns from closed to open. DIAPHRAGM DOWNWARD MOVEMENT Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3137 Based on reed switch input, the PCM de-energizes the LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns from open to closed, allowing the PCM to monitor LDP pumping (diaphragm up/down) activity. During the pumping mode, the diaphragm will not move down far enough to open the vent valve. The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring pressure, slowing the pumping action. The PCM watches the time from when the solenoid is de-energized, until the diaphragm drops down far enough for the reed switch to change from opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it takes the reed switch to change state, the tighter the evaporative system is sealed. If the system pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated. PUMPING ACTION Action : During portions of this test, the PCM uses the reed switch to monitor diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes from open to closed, indicating that the diaphragm has moved down. At other times during the test, the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of rapid cycling, the PCM will use a fixed time interval to cycle the solenoid. If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set: - P0442 - EVAP LEAK MONITOR 0.040 inches LEAK DETECTED - P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED - P0456 - EVAP LEAK MONITOR 0.020 inches LEAK DETECTED Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3138 - P1486 - EVAP LEAK MON PINCHED HOSE FOUND - P1494 - LEAK DETECTION PUMP SW OR MECH FAULT - P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Description and Operation > Leak Detection Pump > Page 3139 Leak Detection Pump: Description and Operation Natural Vac Leak Detection Vehicles equipped with an NGC Powertrain Control Module (PCM) use a Natural Vacuum Leak Detection (NVLD) pump and system. Vehicles equipped with a JTEC PCM use an LDP (Leak Detection Pump). Refer to Leak Detection Pump (LDP) for additional information. The NVLD pump is located in the same area as the leak detection pump. Refer to NVLD Removal/Installation for additional information. The Natural Vacuum Leak Detection (NVLD) system is the new generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller (NGC). This new system replaces the leak detection pump as the method of evaporative system leak detection. This is to detect a leak equivalent to a 0.020 inches (0.5 mm) hole. This system has the capability to detect holes of this size very dependably. The basic leak detection theory employed with NVLD is the "Gas Law". This is to say that the pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel will only see this effect if it is indeed sealed. Even small leaks will allow the pressure in the vessel to come to equilibrium with the ambient pressure. In addition to the detection of very small leaks, this system has the capability of detecting medium as well as large evaporative system leaks. A vent valve seals the canister vent during engine off conditions. If the vapor system has a leak of less than the failure threshold, the evaporative system will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak determination by this diagnostic. When the vacuum in the system exceeds about 1 inches H2O (0.25 KPA), a vacuum switch closes. The switch closure sends a signal to the NGC. The NGC, via appropriate logic strategies, utilizes the switch signal, or lack thereof, to make a determination of whether a leak is present. The NVLD device is designed with a normally open vacuum switch, a normally closed solenoid, and a seal, which is actuated by both the solenoid and a diaphragm. The NVLD is located on the atmospheric vent side of the canister. The NVLD assembly may be mounted on top of the canister outlet, or in-line between the canister and atmospheric vent filter. The normally open vacuum switch will close with about 1 inches H2O (0.25 KPA) vacuum in the evaporative system. The diaphragm actuates the switch. This is above the opening point of the fuel inlet check valve in the fill tube so cap off leaks can be detected. Submerged fill systems must have recirculation lines that do not have the in-line normally closed check valve that protects the system from failed nozzle liquid ingestion, in order to detect cap off conditions. The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system during the engine off condition. If vacuum in the evaporative system exceeds 3 inches to 6 inches H2O (0.75 to 1.5 KPA), the valve will be pulled off the seat, opening the seal. This will protect the system from excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative. The solenoid actuates the valve to unseal the canister vent while the engine is running. It also will be used to close the vent during the medium and large leak tests and during the purge flow check. This solenoid requires an initial 1.5 amps of current to pull the valve open, but after 100 milli-seconds, will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle. Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system. The device will "blow off' at about 0.5 inches H2O (0.12 KPA) pressure to permit the venting of vapors during refueling. An added benefit to this is that it will also allow the tank to "breathe" during increasing temperatures, thus limiting the pressure in the tank to this low level. This is beneficial because the induced vacuum during a subsequent declining temperature will achieve the switch closed (pass threshold) sooner than if the tank had to decay from a built up pressure. The device itself has 3 wires: Switch sense, solenoid driver and ground. It also includes a resistor to protect the switch from a short to battery or a short to ground. The NGC utilizes a high-side driver to energize and duty-cycle the solenoid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump Leak Detection Pump: Service and Repair Leak Detection Pump REMOVAL The Leak Detection Pump (LDP) (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. This is located near the front of the fuel tank. The LDP and LDP filter are replaced (serviced) as one unit. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Carefully remove hose at LDP filter. 4. Remove LDP filter mounting bolt and remove from vehicle. 5. Carefully remove vapor/vacuum lines at LDP. 6. Disconnect electrical connector at LDR 7. Remove LDP mounting bolt and remove LDP from vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3142 The LDP (4) and LDP filter are attached to the front of the EVAP canister mounting bracket. The LDP and LDP filter are replaced (serviced) as one unit. 1. Install LDP to mounting bracket. Refer to Torque Specifications. 2. Install LDP filter to mounting bracket. Refer to Torque Specifications. 3. Carefully install vapor/vacuum lines to LDP, and install hose to LDP filter. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the LDP, LDP filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. Connect electrical connector to LDP. 5. If necessary, install skid plate(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3143 Leak Detection Pump: Service and Repair Natural Vac Leak Detection Pump Equipped With Horizontally Mounted EVAP Canisters REMOVAL The NVLD pump (4) is attached to the EVAP canister. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Disconnect electrical connector at NVLD assembly. 4. Carefully disconnect vapor lines from NVLD assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3144 5. Lift tab on NVLD assembly and twist assembly counterclockwise. 6. Pull NVLD pump out to remove from EVAP canister. 7. Remove O-ring from EVAP canister. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3145 INSTALLATION The NVLD pump (4) is attached to the EVAP canister. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3146 1. Install new O-ring to EVAP canister. 2. Align NVLD assembly into EVAP canister. 3. Rotate NVLD assembly until alignment tab drops into slot. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3147 4. Connect electrical connector to NVLD assembly. 5. Carefully install vapor/vacuum lines to NVLD pump. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the NVLD pump, filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 6. If necessary, install skid plate(s). Equipped With Vertically Mounted EVAP Canisters REMOVAL The NVLD pump (4) is located at the front of fuel tank. 1. Raise and support vehicle. 2. Certain models, equipped with a certain fuel tank size, may require the removal of the fuel tank skid plate and/or the transfer case skid plate to gain access to the leak pump. Remove necessary skid plates. 3. Disconnect electrical connector at pump. 4. Carefully remove vapor/vacuum hoses at pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3148 5. The NVLD pump snaps into the EVAP canister. Press on release tab (2) while rotating pump from canister. INSTALLATION The NVLD pump (4) is located at the front of fuel tank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Leak Detection Pump > Page 3149 1. Snap NVLD pump (1) to EVAP canister until tab (2) engages. 2. Connect electrical connector to NVLD pump. 3. Carefully install vapor/vacuum lines to NVLD pump. The vapor/vacuum lines and hoses must be firmly connected. Check the vapor/vacuum lines at the NVLD pump, filter and EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 4. If equipped, install skid plate(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation The ORVR (On-Board Refueling Vapor Recovery) system consists of a unique fuel tank, flow management valve, fluid control valve, one-way check valve and vapor canister. The ORVR (On-Board Refueling Vapor Recovery) system is used to remove excess fuel tank vapors. This is done while the vehicle is being refueled. Fuel flowing into the fuel filler tube (approx. 1 inches I.D.) creates an aspiration effect drawing air into the fuel fill tube. During refueling, the fuel tank is vented to the EVAP canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the EVAP canister, the vehicle's computer controlled purge system draws vapor out of the canister for the engine to burn. The vapor flow is metered by the purge solenoid so that there is no, or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fuel fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve and on to the vapor canister. Vapor is absorbed in the EVAP canister until vapor flow in the lines stops. This stoppage occurs following fuel shut-off, or by having the fuel level in the tank rise high enough to close the control valve. This control valve contains a float that rises to seal the large diameter vent path to the EVAP canister. At this point in the refueling process, fuel tank pressure increases, the check valve closes (preventing liquid fuel from spiting back at the operator), and fuel then rises up the fuel filler tube to shut off the dispensing nozzle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations EGR Control Solenoid: Locations The electronic EGR valve and solenoid assembly (2) is attached to the front of the right cylinder head. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3157 EGR Control Solenoid: Service and Repair REMOVAL The electronic EGR valve and solenoid assembly (3) is attached to the front of the right cylinder head (1). An exhaust gas routing tube connects the EGR valve to the intake manifold. 1. Disconnect electrical connector (1) from EGR solenoid (2). 2. Remove two bolts (3) connecting EGR tube (4) to valve assembly. 3. Remove gasket located between EGR tube flange and EGR valve assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3158 4. Remove two mounting bolts (2). 5. Separate valve assembly (3) from cylinder head (1). 6. Remove and discard metal gasket located between cylinder head and valve assembly. INSTALLATION 1. Position a new metal gasket between cylinder head (1) and valve assembly (3). 2. Install two mounting bolts (2) and tighten. Refer to Torque Specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 3159 3. Clean EGR tube where it joins EGR valve. 4. Position new gasket between EGR tube flange and EGR valve assembly. 5. Install two bolts (3) connecting EGR tube (4) to valve assembly (2). Tighten bolts. Refer to Torque Specifications. 6. Connect electrical connector (1) to EGR solenoid (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations EGR Valve: Locations The electronic EGR valve and solenoid assembly (2) is attached to the front of the right cylinder head. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3163 Assembly - EGR Valve (4.7L/5.7L LD) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3164 EGR Valve: Description and Operation The electronic EGR valve and solenoid assembly (2) is attached to the front of the right cylinder head. An exhaust gas routing tube (4) connects the EGR valve to the intake manifold. Exhaust gas recirculation flow is determined by the Powertrain Control Module (PCM) and is controlled by an electronic EGR valve assembly. For a given set of conditions, the PCM knows the ideal exhaust gas recirculation flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The PCM adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct position. The electronic EGR valve assembly consists of a pintle, valve seat, and housing which contains and regulates exhaust gas flow. An armature, return spring, and solenoid coil provide the operating force to regulate exhaust gas flow by changing the pintle position. The solenoid coil assembly is wired in parallel with a diode that connects two internal connectors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3165 EGR Valve: Service and Repair REMOVAL The electronic EGR valve and solenoid assembly (3) is attached to the front of the right cylinder head (1). An exhaust gas routing tube connects the EGR valve to the intake manifold. 1. Disconnect electrical connector (1) from EGR solenoid (2). 2. Remove two bolts (3) connecting EGR tube (4) to valve assembly. 3. Remove gasket located between EGR tube flange and EGR valve assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3166 4. Remove two mounting bolts (2). 5. Separate valve assembly (3) from cylinder head (1). 6. Remove and discard metal gasket located between cylinder head and valve assembly. INSTALLATION 1. Position a new metal gasket between cylinder head (1) and valve assembly (3). 2. Install two mounting bolts (2) and tighten. Refer to Torque Specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 3167 3. Clean EGR tube where it joins EGR valve. 4. Position new gasket between EGR tube flange and EGR valve assembly. 5. Install two bolts (3) connecting EGR tube (4) to valve assembly (2). Tighten bolts. Refer to Torque Specifications. 6. Connect electrical connector (1) to EGR solenoid (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations This engine is equipped with a closed crankcase ventilation system and a Positive Crankcase Ventilation (PCV) valve. This system consists of: Fig.12 Location 5.7L PCV Value Fig.13 5.7L PCV Value - a PCV valve mounted into the top of the intake manifold, located to the right / rear of the throttle body. The PCV valve is sealed to the intake manifold with 2 O-rings. - passages in the intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3172 - tubes and hoses to connect the system components. Fig.15 Typical Closed Crankcase Ventilation System The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve and into a passage in the intake manifold. The PCV system manages crankcase pressure and meters blow by gases to the intake system, reducing engine sludge formation. Fig.16 Engine Off Or Engine Backfire - No Vapor Flow The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Fig.17 High Intake Manifold Vacuum - Minimal Vapor Flow Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3173 During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Fig.18 Moderate Intake Manifold Vacuum - Maximum Vapor Flow During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3174 Positive Crankcase Ventilation Valve: Description and Operation The 5.7L V-8 engine is equipped with a closed crankcase ventilation system and a Positive Crankcase Ventilation (PCV) valve (4). This system consists of: - a PCV valve mounted into the top of the intake manifold, located to the right I rear of the throttle body. The PCV valve (1) is sealed to the intake manifold with 2 O-rings (2). - passages in the intake manifold. - tubes and hoses to connect the system components. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3175 A typical enclosed crankcase ventilation system is shown in the graphic. The PCV system operates by engine intake manifold vacuum. Filtered air is routed into the crankcase through the air cleaner hose. The metered air, along with crankcase vapors, are drawn through the PCV valve (4) and into a passage in the intake manifold. The PCV system manages crankcase pressure and meters blow by gases to the intake system, reducing engine sludge formation. The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. When the engine is not operating or during an engine pop-back, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3176 During periods of high manifold vacuum, such as idle or cruising speeds, vacuum is sufficient to completely compress spring. It will then pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. During periods of moderate manifold vacuum, the plunger is only pulled part way back from inlet. This results in maximum vapor flow through the valve. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3177 Positive Crankcase Ventilation Valve: Service and Repair REMOVAL The PCV valve (4) is mounted into the top of the intake manifold (1). This is located to the right I rear of the throttle body (2). 1. The PCV valve is sealed to the intake manifold with 2 O-rings (2). 2. Remove PCV valve by rotating counter-clockwise 90 degrees until locating tabs (3) have been freed. After tabs have cleared, pull valve straight up from intake manifold. 3. After valve is removed, check condition of 2 valve O-rings (2). INSTALLATION 1. Clean out intake manifold opening. 2. Check condition of 2 O-rings on PCV valve. 3. Apply engine oil to 2 O-rings. 4. Place PCV valve into intake manifold and rotate 90 degrees clockwise for installation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3182 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 3183 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by manufacturer. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > Page 3190 Idle Speed: Description and Operation 5.7L: A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair REMOVAL The following procedure applies only to vehicles without the Adjustable Pedal Package (code XAP). The accelerator pedal is serviced as a complete assembly including the bracket. The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (2). This plastic retainer snaps into the top of the accelerator pedal arm. 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) and throttle cable core wire from upper end of accelerator pedal arm. Plastic cable retainer (clip) snaps into pedal arm. 2. Remove 2 accelerator pedal mounting bracket nuts. Remove accelerator pedal assembly. INSTALLATION 1. Place accelerator pedal assembly over 2 studs. 2. Install and tighten 2 mounting nuts. Refer to Torque Specifications. 3. Slide throttle cable into opening slot in top of pedal arm. 4. Push plastic cable retainer (clip) into accelerator pedal arm opening until it snaps into place. 5. Before starting engine, operate accelerator pedal to check for any binding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 3198 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3199 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3200 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3201 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair ELEMENT - AIR CLEANER REMOVAL Filter Element Only Fig. 1 AIR CLEANER COVER Housing removal is not necessary for element (filter) replacement. 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Pry over 4 spring clips (5) from housing cover (3) (spring clips retain cover to housing). 3. Release housing cover (3) from locating tabs (4) on housing and remove cover (3). 4. Remove air cleaner element (filter) from housing. 5. Clean inside of housing before replacing element. Housing Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3206 Fig. 2 AIR CLEANER HOUSING 1. Loosen clamp and disconnect air duct at air cleaner cover. 2. Lift entire housing (1) assembly from 4 locating pins (2). INSTALLATION 1. Install filter element into housing. 2. Position housing cover into housing locating tabs (4). 3. Pry up 4 spring clips (5) and lock cover to housing. 4. Install air duct to air cleaner cover and tighten hose clamp to 3 Nm (30 inch lbs.) torque. 5. If any other hose clamps were removed from air intake system, tighten them to 3 Nm (30 inch lbs.) torque. 6. If any bolts were removed from air resonator housing or air intake tubing, tighten them to 4 Nm (40 inch lbs.) torque. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 3207 7. Install filter housing (1) into locating pins (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Selection ...................................................................................................................................... ................................... 89 Octane, (R+M)/2 Method .............................................................................................................................................. Mid-Grade preferred (87 Octane acceptable) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System MIL ON/DTC P0457 Set Fuel Filler Cap: Customer Interest Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System MIL ON/DTC P0457 Set > Page 3219 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap: All Technical Service Bulletins Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 3225 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: Customer Interest Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 3234 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: All Technical Service Bulletins Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 3240 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair STANDARD PROCEDURE - FUEL SYSTEM PRESSURE RELEASE Use following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove fuel fill cap. 2. Remove fuel pump relay from Power Distribution Center (PDC). For location of relay, refer to label on underside of PDC cover. 3. Start and run engine until it stalls. 4. Attempt restarting engine until it will no longer run. 5. Turn ignition key to OFF position. CAUTION: Steps 1, 2, 3 and 4 must be performed to relieve high pressure fuel from within fuel rail. Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber. 6. Unplug connector from any fuel injector. 7. Attach one end of a jumper wire with alligator clips (18 gauge or smaller) to either injector terminal. 8. Connect other end of jumper wire to positive side of battery. 9. Connect one end of a second jumper wire to remaining injector terminal. CAUTION: Powering an injector for more than a few seconds will permanently damage the injector. 10. Momentarily touch other end of jumper wire to negative terminal of battery for no more than a few seconds. 11. Place a rag or towel below fuel line quick-connect fitting at fuel rail. 12. Disconnect quick-connect fitting at fuel rail. Refer to Quick-Connect Fittings. 13. Return fuel pump relay to PDC. 14. One or more Diagnostic Trouble Codes (DTC s) may have been stored in PCM memory due to fuel pump relay removal. The DRB(R) scan tool must be used to erase a DTC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams Fuel Injector: Diagrams Injector-Fuel - No.1 (NGC) Injector-Fuel - No.2 (NGC) Injector-Fuel - No.3 (NGC) Injector-Fuel - No.4 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3248 Injector-Fuel - No.5 (NGC) Injector-Fuel - No.6 (NGC) Injector-Fuel - No.7 (NGC) Injector-Fuel - No.8 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3249 Fuel Injector: Description and Operation An individual fuel injector (1) is used for each individual cylinder. The top (fuel entry) end of the injector (1) is attached into an opening on the fuel rail. The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The nozzle (outlet) ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. PCM OUTPUT The nozzle ends of the injectors are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector with its respective cylinder number. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3250 Fuel Injector: Service and Repair REMOVAL 1. Remove fuel rail. 2. Disconnect clip(s) that retain fuel injector(s) to fuel rail (2). INSTALLATION 1. Install fuel injector(s) into fuel rail assembly and install retaining clip(s). 2. If same injector(s) is being reinstalled, install new O-ring(s). 3. Apply a small amount of clean engine oil to each injector O-ring. This will aid in installation. 4. Install fuel rail. 5. Start engine and check for fuel leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. CAUTION: - Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. - The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3254 Fuel Line Coupler: Service and Repair STANDARD PROCEDURE - QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. DISCONNECTING WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSE, FITTING OR LINE, FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO FUEL SYSTEM PRESSURE RELEASE PROCEDURE. CAUTION: - Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. - The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. 1. Perform fuel pressure release procedure. 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Single Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting. 5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3255 Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN. 6. Perform fuel pressure release procedure. 7. Disconnect negative battery cable from battery. 8. Clean fitting of any foreign material before disassembly. 9. 2 Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. 10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3256 11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. 12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. 13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab. 14. Raise pull tab until it separates from quick-connect fitting. 15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3257 16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. a. To release fuel system component from quickconnect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 17. Latch Clips Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together. 18. Pry up on latch clip with a screwdriver (3). 19. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3258 20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 21. With special tool still inserted, pull fuel line from fuel rail. 22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 23. Disconnect quick-connect fitting from fuel system component being serviced. 24. Latch Clips Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/ fuel rail connection, or to join fuel lines together. 25. Type 2: Separate and unlatch small arms (1) on end of clip and swing away from fuel line. 26. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 3259 27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 28. With special tool still inserted, pull fuel line from fuel rail. 29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 30. Disconnect quick-connect fitting from fuel system component being serviced. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Fuel Filter/Fuel Pressure Regulator Fuel Pressure Regulator: Locations Fuel Filter/Fuel Pressure Regulator A combination fuel filter and fuel pressure regulator (3) is used on all engines. It is located on the top of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Fuel Filter/Fuel Pressure Regulator > Page 3264 Fuel Pressure Regulator: Locations Fuel Pump Module The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 3265 Fuel Pressure Regulator: Description and Operation A combination fuel filter and fuel pressure regulator (3) is used on all engines. It is located on the top of the fuel pump module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator Operation: The pressure regulator is a mechanical device that is not controlled by engine vacuum or the Powertrain Control Module (PCM). The regulator is calibrated to maintain fuel system operating pressure of approximately 58 ± 2 psi at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator. The regulator acts as a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. A second check valve is located at the outlet end of the electric fuel pump. If fuel pressure at the pressure regulator exceeds approximately 60 psi, an internal diaphragm opens and excess fuel pressure is routed back into the tank through the bottom of pressure regulator. Both fuel filters (at bottom of fuel pump module and within fuel pressure regulator) are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE 58 psi ± 2 psi Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3270 Fuel Pressure: Testing and Inspection Test 1 - 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 3271 Test 3 - 5 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specification - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump - Fuel pump relay output circuit open Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3277 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3278 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3279 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3280 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3281 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3282 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3283 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3284 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3285 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3286 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3287 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3288 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3289 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3290 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3291 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3292 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3293 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3294 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3295 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3296 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 3297 Fuel Pump Relay: Description and Operation A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations Fuel Pump Pickup Filter: Locations The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Locations > Page 3301 Fuel Pump Pickup Filter: Service and Repair FILTER - INLET REMOVAL The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module (1). The fuel pump module is located inside of fuel tank. 1. Remove fuel tank. 2. Remove fuel pump module. 3. Remove filter by carefully prying 2 lock tabs (2) at bottom of module with 2 screwdrivers. Filter is snapped to module. 4. Clean bottom of pump module. INSTALLATION The fuel pump inlet filter (strainer) is located on the bottom of the fuel pump module. The fuel pump module is located inside of fuel tank. 1. Snap new filter to bottom of module. Be sure O-ring is in correct position. 2. Install fuel pump module. 3. Install fuel tank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation The fuel injector rail is used to mount the fuel injectors to the engine. High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or joints. Do not attempt to separate the rail halves at these connecting hose or joints. Due to the design of the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose or joint. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose or joint. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3305 Fuel Rail: Service and Repair REMOVAL 5.7L WARNING: THE FUEL SYSTEM IS UNDER CONSTANT PRESSURE EVEN WITH ENGINE OFF. BEFORE SERVICING FUEL RAIL, FUEL SYSTEM PRESSURE MUST BE RELEASED. CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate rail halves at connector tube. Due to design of tube, it does not use any clamps. Never attempt to install a clamping device of any kind to tube. When removing fuel rail assembly for any reason, be careful not to bend or kink tube. 1. Remove fuel tank filler tube cap. 2. Perform fuel system pressure release procedure. 3. Remove negative battery cable at battery. 4. Remove flex tube (air cleaner housing to engine). 5. Remove air resonator box at throttle body. 6. Disconnect electrical connectors at all 8 fuel injectors. Push red colored slider away from injector (1). While pushing slider, depress tab (2) and remove connector (3) from injector. The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If harness is not tagged, note wiring location before removal. 7. Disconnect electrical connectors at all throttle body sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3306 8. Disconnect fuel supply tube quick connect fitting at the fuel rail. 9. Remove four fuel rail mounting bolts (1) and holddown clamps. 10. Gently rock and pull left side of fuel rail until fuel injectors just start to clear machined holes in intake manifold. Gently rock and pull right side of rail until injectors just start to clear intake manifold head holes. Repeat this procedure (left/right) until all injectors have cleared machined holes. 11. Remove fuel rail (with injectors attached) from engine. 12. Remove fuel injectors if required. INSTALLATION 1. Install fuel injectors if required 2. Clean out fuel injector machined bores in intake manifold. 3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in fuel rail installation. 4. Position fuel rail/fuel injector assembly to machined injector openings in intake manifold. 5. Guide each injector into intake manifold. Be careful not to tear injector O-rings. 6. Push right side of fuel rail down until fuel injectors have bottomed on shoulders. Push left fuel rail down until injectors have bottomed on shoulders. 7. Install 4 fuel rail holddown clamps and 4 mounting bolts (1). 8. Connect electrical connector to throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3307 9. Connect electrical connectors at all fuel injectors. Push connector onto injector (1) and then push and lock red colored slider (2). Verify connector is locked to injector by lightly tugging on connector. 10. Connect fuel line latch clip and fuel line to fuel rail. 11. Install air resonator to throttle body (2 bolts). 12. Install flexible air duct to air box. 13. Connect battery cable to battery. 14. Start engine and check for leaks. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3317 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3318 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3324 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3325 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit Fuel Gauge Sender: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit > Page 3330 Fuel Gauge Sender: Locations Fuel Pump The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3346 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3347 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3348 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3349 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3350 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3351 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 3352 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3353 Fuel Gauge Sender: Description and Operation The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Diagrams > Page 3354 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3363 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3364 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3370 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 3371 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations Chassis Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3375 Module - Fuel Pump Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Locations > Page 3376 Fuel Tank Unit: Service and Repair REMOVAL WARNING: THE FUEL SYSTEM MAY BE UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE FUEL PUMP MODULE, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. 1. Drain and remove fuel tank. 2. Note rotational position of module before attempting removal. An indexing arrow is located on top of module for this purpose. 3. Position Special Tool 9340 (3) into notches on outside edge of lockring (5). 4. Install 1/2 inch drive breaker bar (1) to tool 9340 (3). 5. Rotate breaker bar counter-clockwise to remove lockring (5). 6. Remove lockring. The module will spring up slightly when lockring is removed. 7. Remove module from fuel tank. Be careful not to bend float arm while removing. INSTALLATION 1. Using a new seal (gasket), position fuel pump module into opening in fuel tank. 2. Position lockring (5) over top of fuel pump module. 3. Rotate module until embossed alignment arrow points to center alignment mark. This step must be performed to prevent float from contacting side of fuel tank. Also be sure fuel fitting on top of pump module is pointed to drivers side of vehicle. 4. Install Special Tool 9340 (3) to lockring. 5. Install 1/2 inch drive breaker (1) into Special Tool 9340 (3). 6. Tighten lockring (clockwise) until all seven notches have engaged. 7. Install fuel tank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation Idle Speed/Throttle Actuator - Electronic: Description and Operation 5.7L: A separate IAC motor is not used with the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Description and Operation > Page 3380 Idle Speed/Throttle Actuator - Electronic: Service and Repair The IAC motor is not serviceable on the 5.7L V-8 engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3384 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3385 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3386 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3393 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3394 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3395 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3396 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3397 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3398 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3399 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3400 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3401 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3402 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3403 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3404 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3405 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3406 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3407 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3408 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3409 Fuel Pump Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3413 Fuel Pump Relay: Description and Operation A separate fuel pump realy is no longer used. A circuit within the TIPM (Totally Integrated Power Module) is used to control the electric fuel pump located within the fuel pump module. The TIPM (1) is located in the engine compartment in front of the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation Main Relay (Computer/Fuel System): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3417 Main Relay (Computer/Fuel System): Testing and Inspection ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered Two different types of relays may be used. - Terminal number 30 is connected to battery voltage. For both the ASD and fuel pump relays, terminal 30 is connected to battery voltage at all times. - The PCM grounds the coil side of the relay through terminal number 85. - Terminal number 86 supplies voltage to the coil side of the relay. - When the PCM de-energizes the ASD and fuel pump relays, terminal number 87A connects to terminal 30. This is the Off position. In the off position, voltage is not supplied to the rest of the circuit. Terminal 87A is the center terminal on the relay. - When the PCM energizes the ASD and fuel pump relays, terminal 87 connects to terminal 30. This is the On position. Terminal 87 supplies voltage to the rest of the circuit. The following procedure applies to the ASD and fuel pump relays. 1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an ohmmeter to check the resistance between terminals 85 and 86. The resistance should be 75 ohms ± 5 ohms. 3. Connect the ohmmeter between terminals 30 and 87A. The ohmmeter should show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between terminals 87 and 30. The ohmmeter should not show continuity at this time. 5. Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source. 6. Connect one end of another jumper wire (16 gauge or smaller) to the power side of the 12 volt power source. Do not attach the other end of the jumper wire to the relay at this time. WARNING: DO NOT ALLOW OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THIS TEST. DAMAGE TO OHMMETER MAY RESULT. 7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay. The ohmmeter should now show continuity between relay Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3418 terminals 87 and 30. The ohmmeter should not show continuity between relay terminals 87A and 30. 8. Disconnect jumper wires. 9. Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits. Refer to Diagram/Electrical. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Page 3419 Main Relay (Computer/Fuel System): Service and Repair The ASD relay is located in the Power Distribution Center (PDC) (2). Refer to label on PDC cover for relay location. REMOVAL 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Install relay to PDC. 2. Install cover to PDC. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations Accelerator Pedal Position Sensor: Component Locations The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Component Locations > Page 3425 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3426 Sensor - Accelerator Pedal Position (5.7L/Diesel) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3427 Accelerator Pedal Position Sensor: Description and Operation The Accelerator Pedal Position Sensor (APPS) (1) is located inside the vehicle. It is attached to the accelerator pedal assembly (3). It is used only on 5.7L V-8 gas engines and diesel engines. The Accelerator Pedal Position Sensor (APPS) provides the Powertrain Control Module (PCM) with two DC voltage signals which change as the position of the accelerator pedal changes. One of the DC voltage signals will be half the voltage of the other signal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3428 Accelerator Pedal Position Sensor: Service and Repair REMOVAL CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Disconnect 6 way electrical connector at top of APPS (2). 2. Remove APPS lower mounting bolt (4) and two mounting nuts. 3. Remove pedal and APPS assembly from vehicle. INSTALLATION CAUTION: Do not attempt to separate or remove the Accelerator Pedal Position Sensor (APPS) from the accelerator pedal assembly. The APPS is replaced as an assembly along with the pedal. If sensor is removed from pedal, its electronic calibration may be destroyed. 1. Position pedal and APPS assembly to its mounting bracket. 2. Connect 6 way electrical connector to top of APPS (2). 3. Install APPS lower mounting bolt (4) and two mounting nuts. 4. If necessary, use a Scan Tool to erase any Diagnostic Trouble Codes (DTC s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3432 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Throttle Body: Locations The throttle body is located on the intake manifold. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3436 Throttle Body (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3437 Throttle Body: Description and Operation The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. 5.7L V-8 Engine: The throttle body on the 5.7L engine is an electrically controlled unit. A mechanical cable is not used to connect the throttle body to the accelerator pedal . The Accelerator Pedal Position Sensor (APPS) along with inputs from other sensors sets the throttle blade to pre-determined positions. Except 5.7L V-8 Engine: Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3438 Throttle Body: Service and Repair REMOVAL CAUTION: Do not use spray (carb) cleaners on any part of the throttle body. Do not apply silicone lubricants to any part of the throttle body. 1. Remove air duct and air resonator box at throttle body. 2. Disconnect electrical connector (2) at throttle body. 3. Remove 4 throttle body mounting bolts (4). 4. Remove throttle body from intake manifold. 5. Check condition of throttle body O-ring (2). 6. If the throttle body has been changed, the following procedure must be performed: a. Disconnect negative battery cable from battery. Leave cable disconnected for approximately 90 seconds. b. Reconnect cable to battery. c. Turn ignition switch ON, but do not crank engine. d. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn throttle body electrical parameters. INSTALLATION CAUTION: Do not use spray (carb) cleaners on any part of the throttle body. Do not apply silicone lubricants to any part of the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 3439 1. Clean and check condition of throttle body-to-intake manifold O-ring (2). 2. Clean mating surfaces of throttle body and intake manifold. 3. Install throttle body to intake manifold by positioning throttle body to manifold alignment pins. 4. Install 4 mounting bolts. 5. Install electrical connector. 6. Install air plenum. 7. If the throttle body has been changed, the following procedure must be performed: a. Disconnect negative battery cable from battery. Leave cable disconnected for approximately 90 seconds. b. Reconnect cable to battery. c. Turn ignition switch ON, but do not crank engine. d. Leave ignition switch ON for a minimum of 10 seconds. This will allow PCM to learn throttle body electrical parameters. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair REMOVAL The Throttle Control Cable on the 5.7L V-8 engine connects the accelerator pedal to the Accelerator Pedal Position Sensor (APPS). A separate mechanical cable is not routed to the throttle body. CAUTION: Be careful not to damage or kink cable core wire (within cable sheathing) while servicing accelerator pedal, cables or APPS. 1. From inside vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm. The plastic cable retainer snaps into pedal arm. 2. Remove cable core wire at pedal arm. 3. Remove APPS. 4. From inside vehicle, remove cable clip. 5. Remove cable housing from dash panel and pull cable into engine compartment. 6. Remove cable housing at APPS bracket by pressing on release tab with a small screwdriver. To prevent cable housing breakage, press on tab only enough to release cable from APPS bracket. INSTALLATION 1. Attach cable to Accelerator Pedal Position Sensor (APPS). 2. Push cable housing into rubber grommet and through opening in dash panel. 3. From inside vehicle, install clip holding cable to dashpanel. 4. From inside vehicle, slide throttle cable core wire into opening in top of pedal arm. 5. Push cable retainer (clip) into pedal arm opening until it snaps in place. 6. Before starting engine, operate accelerator pedal to check for any binding. 7. If necessary, use DRB III(R) Scan Tool to erase any APPS Diagnostic Trouble Codes (DTC s) from PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation Throttle Position Sensor: Description and Operation The 3-wire Throttle Position Sensor (TPS) (2) is mounted on the throttle body and is connected to the throttle blade shaft. The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. The 3-wire TPS provides the Powertrain Control Module (PCM) with an input signal (voltage) that represents the throttle blade position of the throttle body. The sensor is connected to the throttle blade shaft. As the position of the throttle blade changes, the output voltage of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the PCM) represents the throttle blade position. The PCM receives an input signal voltage from the TPS. This will vary in an approximate range of from 0.26 volts at minimum throttle opening (idle), to 4.49 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to engine operating conditions, the PCM will adjust fuel injector pulse width and ignition timing. The PCM needs to identify the actions and position of the throttle blade at all times. This information is needed to assist in performing the following calculations: - Ignition timing advance - Fuel injection pulse-width - Idle (learned value or minimum TPS) - Off-idle (0.06 volt) - Wide Open Throttle (WOT) open loop (2.608 volts above learned idle voltage) - Deceleration fuel lean out - Fuel cutoff during cranking at WOT (2.608 volts above learned idle voltage) - A/C WOT cutoff (certain automatic transmissions only) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 3446 Throttle Position Sensor: Service and Repair The 5.7L V-8 engine does not use a separate Throttle Position Sensor (TPS) on the throttle body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications ENGINE FIRING ORDER - 4.7L V-8 4.7L ENGINE DESCRIPTION Fig. 1 The 4.7 liter (287 CID) eight-cylinder engine is an 90° single overhead camshaft engine. The cast iron cylinder block is made up of two different components; the first component is the cylinder bore and upper block, the second component is the bedplate that comprises the lower portion of the cylinder block and houses the lower half of the crankshaft main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3,5 and 7, and the right bank being numbered 2,4,6 and 8. The firing order is 1-8-4-3-6-5-7-2. The engine serial number is located at the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3452 right front side of the engine block (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3453 Firing Order: Mechanical Specifications Fig.55 5.7L Spark Plug Cable Routing Engine Firing Order - 5.7L V-8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3454 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3455 Firing Order ......................................................................................................................................... ......................................................... 1-8-4-3-6-5-7-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3463 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3464 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3465 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3466 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3471 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3472 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3473 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3474 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3475 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil Resistance - 5.7L Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3479 Ignition Coil: Diagrams Coil-Ignition - No.1 (NGC) Coil-Ignition - No.2 (NGC) Coil-Ignition - No.3 (NGC) Coil-Ignition - No.4 (NGC) Coil-Ignition - No.5 (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 3480 Coil-Ignition - No.6 (NGC) Coil-Ignition - No.7 (4.7L/5.7L) Coil-Ignition - No.8 (4.7L/5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Ignition Coil Ignition Coil: Description and Operation Ignition Coil The 5.7L engine uses 8 dedicated and individually fired coils (3) for each pair of spark plugs. Each coil (3) is mounted directly to the top of each spark plug. Each coil is bolted (2) to the valve cover (4). The ignition system is controlled by the Powertrain Control Module (PCM) on all engines. The 5.7L engine uses dual output coils, and 2 spark plugs per cylinder. Each cylinder is equipped with 1 dual-output coil. Meaning one coil mounts directly over one of the dual spark plugs for 1 high-voltage output. Battery voltage is supplied to all of the ignition coils positive terminals from the ASD relay. If the PCM does not see a signal from the crankshaft and camshaft sensors (indicating the ignition key is ON but the engine is not running), it will shut down the ASD circuit. Base ignition timing is not adjustable. By controlling the coil ground circuits, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The PCM adjusts ignition timing based on inputs it receives from: - The engine coolant temperature sensor - The crankshaft position sensor (engine speed) - The camshaft position sensor (crankshaft position) - The manifold absolute pressure (MAP) sensor - The throttle position sensor - Transmission gear selection Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Ignition Coil > Page 3483 Ignition Coil: Description and Operation Ignition Coil Capacitor One coil capacitor (1) is used. It is located in the right rear section of the engine compartment. The coil capacitor(s) help dampen the amount of conducted electrical noise to the camshaft position sensor, crankshaft position sensor, and throttle position sensor. This noise is generated on the 12V supply wire to the ignition coils and fuel injectors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Removal and Installation Ignition Coil: Service and Repair Removal and Installation REMOVAL 1. Disconnect the electrical connector (1) from coil (3). 2. Clean area at base of coil with compressed air before removal. 3. Remove two mounting bolts (2) (note that mounting bolts are retained to coil). 4. Carefully pull up coil (1) from valve cover. 5. Remove coil (1) from vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Removal and Installation > Page 3486 1. Using compressed air, blow out any dirt or contaminants from around top of spark plug. NOTE: Use dielectric grease on each of the spark plug boots before installing the coil. 2. Position ignition coil (1) into valve cover and push onto spark plugs. 3. Install 2 coil mounting bolts (2). Tighten to 7 N.m (62 in.lbs.). 4. Connect electrical connector (1) to coil by snapping into position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Removal and Installation > Page 3487 Ignition Coil: Service and Repair Ignition Coil Capacitor REMOVAL The coil capacitor is located in the right-rear section of the engine compartment. It is attached with a mounting stud and nut. 1. Disconnect electrical connector (5) at capacitor. 2. Remove mounting nut and remove ground strap. 3. Remove capacitor (1). INSTALLATION 1. Position capacitor (1) to mounting stud (2). 2. Position ground strap (3) to mounting stud (2). 3. Tighten nut (4) to 7 N.m (60 in. lbs.) torque. 4. Connect electrical connector (5) to coil capacitor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The 5.7L is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches to the spark plugs. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Ignition Coils - 2 Knock Sensors - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3497 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3498 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3499 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3500 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 3501 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Description and Operation Ignition Relay: Description and Operation The 5.7L is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches to the spark plugs. Two knock sensors (one for each cylinder bank) are used to help control spark knock. The ignition system consists of: - 16 Spark Plugs (2 per cylinder) - 8 Separate, Ignition Coils - 2 Knock Sensors - Powertrain Control Module (PCM) - Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3513 Sensor - Camshaft Position (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3514 Camshaft Position Sensor: Description and Operation The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3515 Camshaft Position Sensor: Service and Repair REMOVAL The Camshaft Position Sensor (CMP) is located on right side of timing chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from cylinder head. 4. Check condition of sensor O-ring. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3516 1. Clean out machined hole in cylinder head. 2. Install sensor (2) into cylinder head with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 N.m (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3521 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3522 Sensor - Crankshaft Position (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3523 Crankshaft Position Sensor: Description and Operation The Crankshaft Position (CKP) (4) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Engine speed and crankshaft position are provided through the CKP (Crankshaft Position) sensor. The sensor generates pulses that are the input sent to the Powertrain Control Module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. A tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3524 Crankshaft Position Sensor: Service and Repair REMOVAL The Crankshaft Position (CKP) sensor (4) is located at the right-rear side of the engine cylinder block. It is positioned and bolted into a machined hole in the engine block. 1. Raise vehicle. 2. Disconnect CKP electrical connector at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor (4) from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. INSTALLATION 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor (4) into engine block with a slight rocking and twisting action. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to cylinder block. If sensor is not flush, damage to sensor mounting tang may result. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3525 4. Install mounting bolt (3) and tighten to 28 N.m (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3530 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3534 Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3535 Knock Sensor: Diagrams Sensor - Knock No.1 (5.7L/SRT) Sensor - Knock No.2 (5.7L/SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3536 Knock Sensor: Description and Operation Two knock sensors are bolted into the cylinder block under the intake manifold 3.7L, 4.7L & 8.3L. Two knock sensors are also used with the 5.7L. These are bolted into each side of the cylinder block (outside) under the exhaust manifold. Two knock sensors are used; one for each cylinder bank. When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3537 Knock Sensor: Service and Repair REMOVAL Two sensors (1) are used. Each sensor is bolted into the outside of cylinder block below the exhaust manifold (3). 1. Raise vehicle. 2. Disconnect knock sensor electrical connector (5). 3. Remove sensor mounting bolt (2). Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove sensor from engine. INSTALLATION 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: - Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). - Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3538 3. Install and tighten mounting bolt (2). Tighten to 20 N.m (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plugs Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 3543 Spark Plug: Mechanical Specifications Gap ...................................................................................................................................................... ................................................... 0.045 in. (1.14mm) Torque ................................................................................................................................................. ................................................... 13 ft. lbs. (18 N-m) Torque critical design. Do not exceed 15 ft. lbs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3544 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. ......................................... Champion - RE14MCC4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 3545 Spark Plug: Description and Operation Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L engines. To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used. Always use the recommended torque when tightening spark plugs. This is especially true when plugs are equipped with tapered seats. Incorrect torque can distort the spark plug and change plug gap. It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head. Remove the spark plugs and examine them for burned electrodes and fouled, cracked or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from the engine. A single plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in the Lubrication and Maintenance section. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled. Also refer to Spark Plug Conditions. CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal and Installation Spark Plug: Service and Repair Removal and Installation REMOVAL Each individual spark plug is located under each ignition coil. Each individual ignition coil must be removed to gain access to each spark plug. 1. Remove necessary air filter tubing at throttle body. 2. Prior to removing ignition coil, spray compressed air around coil base at cylinder head. 3. Prior to removing spark plug, spray compressed air into cylinder head opening. This will help prevent foreign material from entering combustion chamber. 4. Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. Also check condition of ignition coil O-ring and replace as necessary. 5. Inspect spark plug condition. INSTALLATION NOTE: The 4.7L is equipped with copper core ground electrode spark plugs. They must be replaced with the same type/number spark plug as the original. If another spark plug is substituted, pre-ignition will result. Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. 1. Start the spark plug into the cylinder head by hand to avoid cross threading. 2. Tighten spark plugs to 27 N.m (20 ft.lbs.). 3.7L & 4.7L. 3. The 5.7L is equipped with torque critical design spark plugs. Do not exceed 15 ft. lbs. torque. Tighten spark plugs to 18 N.m (13 ft.lbs). NOTE: 5.7L does not use an O-ring 4. Before installing ignition coil(s), check condition of coil O-ring and replace as necessary. To aid in coil installation, apply silicone to coil O-ring. 5. Install ignition coil(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Removal and Installation > Page 3548 Spark Plug: Service and Repair Cleaning CLEANING AND ADJUSTMENT The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file center electrode flat with a small point file or jewelers file before adjusting gap. CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. Adjust spark plug gap with a gap gauging tool (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3556 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3557 Overdrive Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3558 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3561 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3562 Overdrive Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3563 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Pressure Regulating Solenoid: Description and Operation 42RLE Automatic Transmission Solenoid Pressure Control SOLENOID - PRESSURE CONTROL DESCRIPTION The pressure control solenoid (1) is mounted on the top of the valve body, next to the line pressure sensor (2). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The pressure control solenoid (PCS) is a variable force (VFS) style solenoid. A VFS solenoid is an electrohydraulic actuator, combining a solenoid and a regulating valve. The transmission control module varies the current for the PCS, which varies the pressure in the line pressure hydraulic circuit. When the current (duty cycle) of the PCS is low, the pressure in the circuit is higher. At 0 current (0% duty cycle), the pressure is at the maximum value. Conversely, when the current is maximized (100% duty cycle), the pressure in the circuit is at the lowest possible value. Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3569 The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3570 gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3571 Pressure Regulating Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3572 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Pressure Regulating Solenoid: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3575 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Solenoid Pressure Control SOLENOID PRESSURE CONTROL REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3576 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3577 Pressure Regulating Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3578 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3582 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3583 Solenoid - Brake Transmission Shift Interlock Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shift Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3589 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3590 Shift Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission Valve-Solenoid Switch VALVE-SOLENOID SWITCH DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the L/R-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and 5th (if applicable) gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3591 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3594 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3595 Shift Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3596 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - M/T > Shift Solenoid, M/T > Component Information > Description and Operation Shift Solenoid: Description and Operation SOLENOID REVERSE LOCKOUT DESCRIPTION The reverse lockout solenoid prevents shifting into reverse when the vehicle speed is greater than 5 mph. Solenoid is threaded into the left side of the transmission. OPERATION When vehicle speed is less than 5 mph, the PCM provides a ground for the solenoid (energized) and allows shifting. When vehicle speed is greater than 5 mph, the solenoid is deactivated and prevents the transmission from being shifted into reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. The overdrive off indicator gives an indication to the vehicle operator when the overdrive off feature has been selected using the tow/haul switch, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the overdrive off indicator for the following reasons: - Overdrive Off Lamp-On Message - Each time the cluster receives an overdrive off lamp-on message from the PCM indicating that the overdrive off feature has been selected, the overdrive off indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive off lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive off lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the overdrive off indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 3607 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text "TOW/HAUL" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the tow/haul feature has been selected using the tow/haul switch, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the transmission temperature sensor, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type and model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Controller Area Network (CAN) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the Transmission Range Sensor (TRS), then sends the proper gear selector indicator position messages to the instrument cluster. On vehicles without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, refer to testing. For further diagnosis of the TRS on vehicles without a TCM, refer to Transmission and Drivetrain/Automatic Transmission/ Transaxle. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition ON voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 3619 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift and shift points, depending on the present operating conditions and driver demand. This is possible through control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the Quick Learn Procedure must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 3620 By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the Monitors display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE 545RFE SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 3621 Part 1 Part 2 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3626 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3627 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3628 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3629 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3630 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3631 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3632 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3633 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3634 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3635 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3636 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3637 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3638 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3639 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3640 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3641 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3642 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3643 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3644 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 3645 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description Transmission Control System Relay: Description and Operation Description DESCRIPTION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description > Page 3648 Transmission Control System Relay: Description and Operation Operation OPERATION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 3654 Sensor - Line Pressure (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Description and Operation 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3657 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE DESCRIPTION The line pressure sensor (2) is mounted on the top of the valve body, next to the pressure control solenoid 0). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3658 Fluid Pressure Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Line Pressure SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3659 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3662 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3663 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3664 Fluid Pressure Sensor/Switch: Service and Repair 45RFE/545RFE Automatic Transmission Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3665 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Sensor-Line Pressure SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pres sure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3666 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 3670 Switch - Tow/Haul Overdrive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Switch: Description and Operation 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3673 Overdrive Switch: Description and Operation 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3676 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3677 Overdrive Switch: Service and Repair 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3678 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 3682 Switch - Clutch Interlock (M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3687 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3688 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3689 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3692 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3693 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3694 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 3698 Transmission Speed Sensor: Diagrams Sensor - Input Speed (RFE/RLE) Sensor - Output Speed (RFE/RLE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Speed Sensor: Description and Operation 42RLE Automatic Transmission Sensor Output Speed SENSOR OUTPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor Input Speed SENSOR INPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3701 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3702 Transmission Speed Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Speed Sensor: Service and Repair 42RLE Automatic Transmission Sensor Input Speed SENSOR INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor (1) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor Output Speed SENSOR OUTPUT SPEED REMOVAL 1. Raise vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3705 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor(2). NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor (2) from the transmission case. INSTALLATION 1. Install the output speed sensor (2) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3706 Transmission Speed Sensor: Service and Repair 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the trans mission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor-Output Speed SENSOR-OUTPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3707 3. Remove the wiring connector from the output speed sensor(1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Temperature Sensor/Switch: Description and Operation 42RLE Automatic Transmission Sensor Transmission Range SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Sensor Transmission Temperature SENSOR TRANSMISSION TEMPERATURE DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3712 The transmission temperature sensor (2) is located in the transmission range sensor (1) and communicates transmission sump temperature to the TCM. OPERATION The transmission range sensor (TRS) has an integrated thermistor that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The TCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3713 Transmission Temperature Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Temperature SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 3714 Transmission Temperature Sensor/Switch: Service and Repair SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 3715 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3724 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3725 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3726 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3727 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0340/P0344 Set NUMBER: 18-015-09 GROUP: Vehicle Performance DATE: May 9, 2009 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: MIL Illumination Due To Diagnostic Trouble Code P0340 Or P0344 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2002-2003 DN Durango 2002 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (DR) Ram Truck 2004 (AN) Dakota 2005-2006 (ND) Dakota 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2006 (PT) Chrysler PT Cruiser 2005 - 2006 (TJ) Wrangler 2005 - 2006 (TJ) Wrangler (International) NOTE: This bulletin applies to: ^ DR vehicles equipped with a 3.7L/4.7L/5.7L engine (sales code EKG, EVA, EVD, EZA or EZB) ^ 2002 LH vehicles equipped with a 2.7L or 3.5L engine (sales code EER, EES, EGG, EGG, EGK or EGJ) ^ 2003 and 2004 LH vehicles equipped with a 2.7L engine (sales code EER) ^ LX/LE vehicles equipped with a 2.7L/3.5L or 5.7L engine (sales code EER, EGG or EZB) ^ JR vehicles equipped with a 2.7L engine (sales code EER or EER) ^ TJ vehicles equipped with a 4.0L engine (sales code ERH) ^ AN vehicles equipped with a 3.7L or 4.7L engine (sales code EGK or EVA) ^ ND vehicles equipped with a 3.7L or 4.7L engine (sales code EGK, EVA or EVC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3732 ^ PT vehicles equipped with a 2.4L engine (sales code EDZ) ^ DN vehicles equipped with a 4.7L engine (sales code EVA) SYMPTOM/CONDITION: The software contains the following improvements for all customers: ^ A MIL illumination for P0340 - Camshaft Position Sensor Circuit - Bank 1 Sensor 1 ^ A MIL illumination for P0344 - Camshaft Position Sensor Intermittent - Bank 1 Sensor 1 DIAGNOSIS: Using a Scan Tool (DRBIII(R) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TECHCONNECT, Refer To 8 Electrical/Electronic Control Modules/Powertrain Control Module - Standard Procedure PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach it near the VECI label. REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3733 NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3734 NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE FOR EXPORT VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2006 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. 3. Log into DealerCONNECT. Proceed to: Service / Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3735 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-008-08A > Mar > 08 > Engine Controls - DTC P1521 Incorrect Engine Oil Type PROM - Programmable Read Only Memory: Customer Interest Engine Controls - DTC P1521 Incorrect Engine Oil Type NUMBER: 18-008-08 REV. A GROUP: Vehicle Performance DATE: March 15, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-08, DATED FEBRUARY 21, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Diagnostic Trouble Code P1521 - Incorrect Engine Oil Type Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2006 (DR) Ram Truck 2006 (HB) Durango 2006 (LX) 300/Magnum/Charger 2006 (LE) 300C/300 Touring (International Markets) 2006 (WK) Grand Cherokee 2006 (WH) Grand Cherokee (International Markets) 2006 (XK) Commander 2006 (XH) Commander (International Markets) NOTE: This bulletin applies to models equipped with a 5.7L engine (sales code EZB). SYMPTOM/CONDITION: Investigation by the technician with the StarSCAN(R) may find that a Diagnostic Trouble Code (DTC) is set with no other symptoms or conditions. The DTC that will be set is P1521 - Incorrect Engine Oil Type. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If other DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle experiences the DTC listed above, with no other Symptom/Condition or other DTC, perform the Repair Procedure. After the Repair Procedure inform the customer that: 1. The correct oil type must be used when a oil change is required. 2. If the MIL light comes on again after the flash, and it is for P1521 - Incorrect Engine Oil Type that an oil change is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-008-08A > Mar > 08 > Engine Controls - DTC P1521 Incorrect Engine Oil Type > Page 3740 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TECHCONNECT, Refer To 8 - Electrical/Electronic Control Modules/Powertrain Control Module - Standard Procedure PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-027-07 > Apr > 07 > Engine Controls - MIL ON/DTC's P0404/P0405/P0406 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P0404/P0405/P0406 NUMBER: 18-027-07 GROUP: Vehicle Performance DATE: April 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. SUBJECT: Flash: MIL Illumination Due To EGR Position Sensor DTC - P0404, P0405, or P0406 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2006 - 2007 (DR) Ram Truck (1500) 2006-2007 (HB/HG) Durango/Aspen 2006 - 2007 (LX/LE) 300 / Magnum / Charger 2006-2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK / XH) Commander NOTE: This bulletin applies to vehicles equipped with a 5.7L engine with MDS (sales code EZB) built on or before February 15, 2007 (MDH 0215XX). SYMPTOM/CONDITION: The vehicle operator may experience a Malfunction Indicator Lamp (MIL) illumination due to one or more of the following Diagnostic Trouble Codes (DTC): ==> P0404 - EGR Position Sensor Performance ==> P0405 - EGR Position Sensor Circuit Low ==> P0406 - EGR Position Sensor Circuit High DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-027-07 > Apr > 07 > Engine Controls - MIL ON/DTC's P0404/P0405/P0406 > Page 3745 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-027-07 > Apr > 07 > Engine Controls - MIL ON/DTC's P0404/P0405/P0406 > Page 3746 j. Select "Update Controller". k. When the update is complete, select "OK". NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-06 > May > 06 > Engine Controls - MIL ON/DTC's P2112 or P1521 PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC's P2112 or P1521 NUMBER: 18-018-06 GROUP: Vehicle Performance DATE: May 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-035-05 REV. A, DATED NOVEMBER 18, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE 2006 LX/LE 6.1L CLEAN POINT. SUBJECT: FLASH: MIL Illumination At Start-Up Due To DTC P2112 Or P1521 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2006 (DR) Ram Truck 2006 (HB) Durango 2005 - 2006 (LX/LE) 300 / Magnum / Charger 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to: Grand Cherokee and Commander vehicles equipped with a 5.7L engine (sales code EZB) built prior to September 08, 2005 (MDH 0908XX); or to Ram Truck vehicles equipped with a 5.7L engine (sales code EZB) built prior to October 27, 2005 (MDH 1027XX); or to Durango vehicles equipped with a 5.7L engine (sales code EZB) built prior to September 24, 2005 (MDH 0924XX); or to 300, Magnum, and Charger vehicles equipped with a 5.7L engine (sales code EZB) built prior to September 03, 2005 (MDH 0903XX); or to 300, Magnum, and Charger vehicles equipped with a 6.1 L engine (sales code ESF) built prior to **April 17, 2006 (MDH 0417XX)**. SYMPTOM/CONDITION: The vehicle operator may experience a Malfunction Indicator Lamp (MIL) illumination due to one of the following Diagnostic Trouble Codes (DTC): P2112 - Electronic Throttle Control - Unable To Open. If this DTC occurs, it will set at time of engine start up. This condition may affect all vehicles listed above, except Durango (HB) and Ram Truck (DR). P1521 - Incorrect Engine Oil Type. This DTC may set in high ambient temperature conditions when the correct oil type (viscosity) is being used in the engine. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-06 > May > 06 > Engine Controls - MIL ON/DTC's P2112 or P1521 > Page 3751 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating system in the StarSCAN(R) must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the PCM update is complete, select "OK". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-06 > May > 06 > Engine Controls - MIL ON/DTC's P2112 or P1521 > Page 3752 l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 NUMBER: 21-009-09 GROUP: Transmission DATE: November 14, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-005-07, DATED MARCH 20, 2007 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF 2004 AN AND KJ MODEL YEAR PCM SOFTWARE. THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.01 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT, StarMOBILE or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII®; MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: 42RLE - Improved Hill Climb Capability In Reverse Or DTC's P17131 P1776 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: **2004 (AN) Dakota** 2006 (DR) Ram Truck 2005-2006 (HB) Durango **2004** - 2006 (KJ) Liberty / Cherokee 2005-2006 (ND) Dakota 2005 (TJ) Wrangler NOTE: This bulletin applies to vehicles equipped with a 42RLE transmission (sales codes DG6 or DGV). SYMPTOM/CONDITION: A. The vehicle operator may experience a low torque condition from the vehicle powertrain that may reduce the capability of the vehicle to ascend certain grades/hills when the transmission is in reverse gear (while backing up). B. The customer may experience, separate from the above low torque condition, a Malfunction Indicator Lamp (MIL) illumination due to one of the following transmission related Diagnostic Trouble Codes (DTC's): - P1713 - Restricted Manual Valve In T2 Range. - P1776 - Solenoid Switch Valve Latched In LR Position. Prior to the MIL illumination for one of the above transmission related DTC's, the customer may not have experienced any transmission related driveability conditions. DIAGNOSIS: Using a Scan Tool (DRBIII(R), StarSCAN(R) or wiTech) with the appropriate Diagnostic Procedures verify all engine systems are functioning as designed. If DTCs other then those listed above are present record them on the repair order and repair as necessary before proceeding further with this Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3758 bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The 2005 KJ will require electrical isolation (disconnect) of the Controller Anti-Lock Brake (CAB) module during the PCM reprogramming process. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: VEHICLES UPDATED USING DRBIII(R) NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. VEHICLES UPDATED USING StarSCAN(R) REPAIR PROCEDURE - USING DRB III(R) TO RETRIEVE THE FLASH FILE FROM TECHCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. Current DRBIII(R) revision level is 63.3 or higher. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). NOTE: Remove any unnecessary PCMCIA cards prior to starting a DRB III(R) flash. 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3759 b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2007 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step #2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the download/update process from TechCONNECT to the DRBIII(R) is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. b. Disconnect the electrical harness connector from the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. 12. Connect the DRBIII(R) to the vehicle. 13. Turn the ignition to the "Run" position (engine not running). 14. Download the flash from the DRBIII(R) to the vehicle PCM. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the PCM flash process is complete, proceed to the next step. 15. If the vehicle is a 2004 or 2005 KJ: a. Turn the ignition switch to the "OFF" position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3760 b. Connect the electrical harness connector to the Controller Anti-Lock Brake (CAB) module. c. Turn the ignition switch to the "ON" position, do not start vehicle. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 16. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE - USING StarSCAN(R) TO RETRIEVE THE FLASH FILE FROM THE INTERNET: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN®; must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service> StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN® Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on thewebsite under the "Download Center". NOTE: If this flash process is interruptedlaborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home ■ screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top f the "Flash PCM screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-009-09 > Nov > 09 > Engine Controls - Low Power In Rev./MIL/DTCs P1713/P1776 > Page 3761 k. When the update is complete, select "OK". 6. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the ECU programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 7. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0340/P0344 Set NUMBER: 18-015-09 GROUP: Vehicle Performance DATE: May 9, 2009 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.05 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. WHENEVER A MODULE IS REPROGRAMMED, THE SOFTWARE IN THE DRBIII(R); MUST BE PROGRAMMED WITH THE LATEST REVISION LEVEL AVAILABLE. SUBJECT: Flash: MIL Illumination Due To Diagnostic Trouble Code P0340 Or P0344 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2002-2003 DN Durango 2002 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 2005 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (DR) Ram Truck 2004 (AN) Dakota 2005-2006 (ND) Dakota 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2006 (PT) Chrysler PT Cruiser 2005 - 2006 (TJ) Wrangler 2005 - 2006 (TJ) Wrangler (International) NOTE: This bulletin applies to: ^ DR vehicles equipped with a 3.7L/4.7L/5.7L engine (sales code EKG, EVA, EVD, EZA or EZB) ^ 2002 LH vehicles equipped with a 2.7L or 3.5L engine (sales code EER, EES, EGG, EGG, EGK or EGJ) ^ 2003 and 2004 LH vehicles equipped with a 2.7L engine (sales code EER) ^ LX/LE vehicles equipped with a 2.7L/3.5L or 5.7L engine (sales code EER, EGG or EZB) ^ JR vehicles equipped with a 2.7L engine (sales code EER or EER) ^ TJ vehicles equipped with a 4.0L engine (sales code ERH) ^ AN vehicles equipped with a 3.7L or 4.7L engine (sales code EGK or EVA) ^ ND vehicles equipped with a 3.7L or 4.7L engine (sales code EGK, EVA or EVC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3766 ^ PT vehicles equipped with a 2.4L engine (sales code EDZ) ^ DN vehicles equipped with a 4.7L engine (sales code EVA) SYMPTOM/CONDITION: The software contains the following improvements for all customers: ^ A MIL illumination for P0340 - Camshaft Position Sensor Circuit - Bank 1 Sensor 1 ^ A MIL illumination for P0344 - Camshaft Position Sensor Intermittent - Bank 1 Sensor 1 DIAGNOSIS: Using a Scan Tool (DRBIII(R) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING StarSCAN AND THE INTERNET TO RETRIEVE THE FLASH FILE: 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TECHCONNECT, Refer To 8 Electrical/Electronic Control Modules/Powertrain Control Module - Standard Procedure PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach it near the VECI label. REPAIR PROCEDURE FOR DOMESTIC VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3767 NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2005 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3768 NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label. REPAIR PROCEDURE FOR EXPORT VEHICLES USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2006 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. g. Disconnect the DRBIII(R) from the vehicle. h. Connect the DRBIII(R) to the ITIL/ISIS PC and NULL modem cable. 3. Log into DealerCONNECT. Proceed to: Service / Repair - Flash. 4. Select vehicle Year, Model, and Engine (YME). Then select the "Submit" button at the bottom of the screen. 5. Compare the calibration part number available for flash reprogramming to the module part number recorded earlier. Select the new calibration if applicable. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-015-09 > May > 09 > Engine Controls - MIL ON/DTC's P0340/P0344 Set > Page 3769 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-008-08A > Mar > 08 > Engine Controls - DTC P1521 Incorrect Engine Oil Type PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - DTC P1521 Incorrect Engine Oil Type NUMBER: 18-008-08 REV. A GROUP: Vehicle Performance DATE: March 15, 2008 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-008-08, DATED FEBRUARY 21, 2008, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 8.04 OR HIGHER FOR THIS BULLETIN. StarMOBILE STANDALONE MODE OR StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: Diagnostic Trouble Code P1521 - Incorrect Engine Oil Type Set OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2006 (DR) Ram Truck 2006 (HB) Durango 2006 (LX) 300/Magnum/Charger 2006 (LE) 300C/300 Touring (International Markets) 2006 (WK) Grand Cherokee 2006 (WH) Grand Cherokee (International Markets) 2006 (XK) Commander 2006 (XH) Commander (International Markets) NOTE: This bulletin applies to models equipped with a 5.7L engine (sales code EZB). SYMPTOM/CONDITION: Investigation by the technician with the StarSCAN(R) may find that a Diagnostic Trouble Code (DTC) is set with no other symptoms or conditions. The DTC that will be set is P1521 - Incorrect Engine Oil Type. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If other DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle experiences the DTC listed above, with no other Symptom/Condition or other DTC, perform the Repair Procedure. After the Repair Procedure inform the customer that: 1. The correct oil type must be used when a oil change is required. 2. If the MIL light comes on again after the flash, and it is for P1521 - Incorrect Engine Oil Type that an oil change is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-008-08A > Mar > 08 > Engine Controls - DTC P1521 Incorrect Engine Oil Type > Page 3774 PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: 1. Reprogram the PCM with the latest software. Follow the detailed service procedures available in DealerCONNECT/TECHCONNECT, Refer To 8 - Electrical/Electronic Control Modules/Powertrain Control Module - Standard Procedure PCM/ECM Programming - Gas. 2. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach it near the VECI label. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-027-07 > Apr > 07 > Engine Controls - MIL ON/DTC's P0404/P0405/P0406 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P0404/P0405/P0406 NUMBER: 18-027-07 GROUP: Vehicle Performance DATE: April 17, 2007 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. SUBJECT: Flash: MIL Illumination Due To EGR Position Sensor DTC - P0404, P0405, or P0406 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2006 - 2007 (DR) Ram Truck (1500) 2006-2007 (HB/HG) Durango/Aspen 2006 - 2007 (LX/LE) 300 / Magnum / Charger 2006-2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK / XH) Commander NOTE: This bulletin applies to vehicles equipped with a 5.7L engine with MDS (sales code EZB) built on or before February 15, 2007 (MDH 0215XX). SYMPTOM/CONDITION: The vehicle operator may experience a Malfunction Indicator Lamp (MIL) illumination due to one or more of the following Diagnostic Trouble Codes (DTC): ==> P0404 - EGR Position Sensor Performance ==> P0405 - EGR Position Sensor Circuit Low ==> P0406 - EGR Position Sensor Circuit High DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DIG's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-027-07 > Apr > 07 > Engine Controls - MIL ON/DTC's P0404/P0405/P0406 > Page 3779 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R) must be programmed with software release level 7.03 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old ECU part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close after the download is complete, then select "Back". i. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-027-07 > Apr > 07 > Engine Controls - MIL ON/DTC's P0404/P0405/P0406 > Page 3780 j. Select "Update Controller". k. When the update is complete, select "OK". NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Flash Reprogramming Abort Recovery NUMBER: 18-001-06 REV. A GROUP: Vehicle Performance DATE: July 12, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY. SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts. MODELS: **2007 (DC) Ram Cab & Chassis** 2006 - **2007** (DR/DH/D1) Ram Truck 2004 - **2007** (HB/HG) Durango/Aspen 2007 (JK) Wrangler **2007 (JS) Sebring** **2007 (KA) Nitro** 2006 - **2007** (KJ) Liberty/Cherokee 2005 - **2007** (LX/LE) 300/Magnum/Charger **2007 (MK) Compass** 2005 - **2007** (ND) Dakota **2007 (PM) Caliber** 2006 - **2007* (PT) PT Cruiser 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK/XH) Commander DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable. Replacing a module that is recoverable is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent unnecessary replacement of control modules. GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service Information). CAUTION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 3785 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 3786 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 3787 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-06 > May > 06 > Engine Controls - MIL ON/DTC's P2112 or P1521 PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC's P2112 or P1521 NUMBER: 18-018-06 GROUP: Vehicle Performance DATE: May 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-035-05 REV. A, DATED NOVEMBER 18, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO THE 2006 LX/LE 6.1L CLEAN POINT. SUBJECT: FLASH: MIL Illumination At Start-Up Due To DTC P2112 Or P1521 OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2006 (DR) Ram Truck 2006 (HB) Durango 2005 - 2006 (LX/LE) 300 / Magnum / Charger 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to: Grand Cherokee and Commander vehicles equipped with a 5.7L engine (sales code EZB) built prior to September 08, 2005 (MDH 0908XX); or to Ram Truck vehicles equipped with a 5.7L engine (sales code EZB) built prior to October 27, 2005 (MDH 1027XX); or to Durango vehicles equipped with a 5.7L engine (sales code EZB) built prior to September 24, 2005 (MDH 0924XX); or to 300, Magnum, and Charger vehicles equipped with a 5.7L engine (sales code EZB) built prior to September 03, 2005 (MDH 0903XX); or to 300, Magnum, and Charger vehicles equipped with a 6.1 L engine (sales code ESF) built prior to **April 17, 2006 (MDH 0417XX)**. SYMPTOM/CONDITION: The vehicle operator may experience a Malfunction Indicator Lamp (MIL) illumination due to one of the following Diagnostic Trouble Codes (DTC): P2112 - Electronic Throttle Control - Unable To Open. If this DTC occurs, it will set at time of engine start up. This condition may affect all vehicles listed above, except Durango (HB) and Ram Truck (DR). P1521 - Incorrect Engine Oil Type. This DTC may set in high ambient temperature conditions when the correct oil type (viscosity) is being used in the engine. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-06 > May > 06 > Engine Controls - MIL ON/DTC's P2112 or P1521 > Page 3792 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating system in the StarSCAN(R) must be programmed with software release level 6.06 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old PCM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the PCM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash PCM" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the PCM update is complete, select "OK". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-06 > May > 06 > Engine Controls - MIL ON/DTC's P2112 or P1521 > Page 3793 l. Verify the part number at the top of the "Flash PCM" screen has updated to the new part number. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. NOTE: The following step is required by law when reprogramming a PCM and/or TCM. 6. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Flash Reprogramming Abort Recovery NUMBER: 18-001-06 REV. A GROUP: Vehicle Performance DATE: July 12, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-001-06, DATED JANUARY II, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, YEARS AND A REVISED DISCUSSION ABOUT ABORTED FLASH REPROGRAMMING RECOVERY. SUBJECT: StarSCAN(R)/StarMOBILE(TM) Abort Recovery Procedures OVERVIEW: This Bulletin provides guidelines to minimize flash reprogramming problems and recovery procedure information for failed flash attempts. MODELS: **2007 (DC) Ram Cab & Chassis** 2006 - **2007** (DR/DH/D1) Ram Truck 2004 - **2007** (HB/HG) Durango/Aspen 2007 (JK) Wrangler **2007 (JS) Sebring** **2007 (KA) Nitro** 2006 - **2007** (KJ) Liberty/Cherokee 2005 - **2007** (LX/LE) 300/Magnum/Charger **2007 (MK) Compass** 2005 - **2007** (ND) Dakota **2007 (PM) Caliber** 2006 - **2007* (PT) PT Cruiser 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK/XH) Commander DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable. Replacing a module that is recoverable is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent unnecessary replacement of control modules. GENERAL: Flash Reprogramming is only authorized when programming a generic module or by a specific SERVICE ACTION (Service Bulletin/Recall/Rapid Response Transmittal/Advance Service Information). CAUTION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 3799 When updating a module because of a Service Action, it is important to follow the steps outlined in the Repair Procedure section of the Service Action. Procedures may differ depending on the module that is being reprogrammed. Review the entire Service Action prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Action. COMMON CAUSES OF FLASH REPROGRAMMING ERRORS Interruptions, voltage problems, a variety of other outside interactions, and failure to follow the steps outlined in the Service Action can potentially interfere with the process. This document seeks to provide information to minimize problems associated with module flash reprogramming. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session, make sure you have the most current software installed in the scan tool (StarSCAN(R)/StarMOBILE(TM)). Refer to the current software release information available in TechCONNECT, under: Service Info > StarSCAN(R) and StarMOBILE(TM) Tools > Latest News > Select the most recent release number. The technician will be able to see the applicable version numbers. Often, because of multiple StarSCAN(R)/StarMOBILE(TM)s in the shop, not all devices will get updated in a timely manner. The installed StarSCAN(R)/StarMOBILE(TM) software version and scan tool operating system version, (Fig. 2), can be verified from the "Home" screen as follows: StarMOBILE Desktop Client ^ Select "Tool Menu". ^ Select "Version Information" Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 3800 StarSCAN ^ Select "Show Shortcuts" ^ Select "Tool Menu". ^ Select "Version Information" Typical Tool Menu (Fig. 1) NOTE: The StarSCAN also displays the version number on the right side of the blue header at the top of each screen. NOTE: To read the version on the StarMOBILE(TM), it must be connected and the application running or the user will receive "N/A" for the "System" value. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. It is a good practice to have dedicated cables devoted to "Flash ONLY". Always have a spare StarSCAN(R) CH9404 (vehicle) cable available. Always have a spare StarMOBILE(TM) CH9804 (vehicle) cable available (blue cable end). Diagnosing vehicle cable problems Inspect vehicle cable connectors for potential problems that might cause communication interruptions. Use the information available on DealerCONNECT under: ^ eSupport (above the "Marketing" tab) ^ Under "Knowledge Center" - select "Find Answers" ^ In the "Enter link, error message, or topic" area, type "561" ^ In the "Search By" area, select "Answer ID" ^ At the next screen, select the "StarSCAN Flash Lockup.pdf" link to access the information to diagnose suspect vehicle cable continuity. FLASH REPROGRAMMING PROBLEM PREVENTION ^ Follow the steps outlined in the Service Action. ^ Pay attention to the screen prompts displayed during the flash process. ^ Replace worn cables. ^ Verify the vehicle is equipped with a known good battery. ^ Ensure the battery charger charging rate provides approximately 13.2 - 13.8 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. **ABORTED FLASH REPROGRAMMING RECOVERY** ** The following steps may help recover a non-responsive module when the flash process is aborted or interrupted. 1. When the Flash ECU screen displays an Error Message, select OK. 2. Turn the ignition to "off" and power down the StarSCAN(R). 3. Turn the vehicle ignition to the "On" position. 4. Power on the StarSCAN®. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-001-06A > Jul > 06 > Engine Controls - Flash Reprogramming Abort Recovery > Page 3801 NOTE: If the technician was flashing a PCM, the tool may display "Unknown VIN". Disregard this. 5. Select (ECU) View. 6. Highlight the ECU that was being flashed. NOTE: The module may appear to be non-responsive. Highlight the module anyway. 7. Select More Options 8. Select ECU Flash 9. If the "Flash ECU" screen displays "Resident flash files for Part # XXXXX", the module should be recoverable. If the screen displays "No resident flash files found" the module is not recoverable. Does the Flash ECU screen display "No resident flash files found?" a. Yes >> The module must be replaced. b. No >> proceed to Step # 10. 10. Is a calibration file displayed on the StarSCAN(R)? a. Yes >> proceed to Step # 11. b. No >> Select "Browse For New File" and follow on screen instructions. Highlight the calibration that was previously chosen. Select "Download to Scantool". When the file is downloaded to the scantool, select "Back" and proceed to Step # 11. 11. Highlight the appropriate calibration. 12. Select "Update Controller" and follow the on screen instructions. 13. When the flash is complete, verify the "Resident flash file part number" matches the 'New PIN" of the appropriate calibration. 14. Proceed with the steps listed in the Service Bulletin to complete the service action.** NOTE: If after following the steps above, you are still having issues performing the flash reprogramming procedure using a specific StarSCAN(R)/StarMOBILE(R) it is suggested to contact SPX/Miller Special Tools for service. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3809 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3810 Overdrive Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3811 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3814 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3815 Overdrive Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3816 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Pressure Regulating Solenoid: Description and Operation 42RLE Automatic Transmission Solenoid Pressure Control SOLENOID - PRESSURE CONTROL DESCRIPTION The pressure control solenoid (1) is mounted on the top of the valve body, next to the line pressure sensor (2). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The pressure control solenoid (PCS) is a variable force (VFS) style solenoid. A VFS solenoid is an electrohydraulic actuator, combining a solenoid and a regulating valve. The transmission control module varies the current for the PCS, which varies the pressure in the line pressure hydraulic circuit. When the current (duty cycle) of the PCS is low, the pressure in the circuit is higher. At 0 current (0% duty cycle), the pressure is at the maximum value. Conversely, when the current is maximized (100% duty cycle), the pressure in the circuit is at the lowest possible value. Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3822 The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3823 gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3824 Pressure Regulating Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3825 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Pressure Regulating Solenoid: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3828 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Solenoid Pressure Control SOLENOID PRESSURE CONTROL REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3829 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3830 Pressure Regulating Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3831 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3835 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3836 Solenoid - Brake Transmission Shift Interlock Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shift Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3842 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3843 Shift Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission Valve-Solenoid Switch VALVE-SOLENOID SWITCH DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the L/R-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and 5th (if applicable) gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3844 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3847 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3848 Shift Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3849 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - M/T > Shift Solenoid, M/T > Component Information > Description and Operation Shift Solenoid: Description and Operation SOLENOID REVERSE LOCKOUT DESCRIPTION The reverse lockout solenoid prevents shifting into reverse when the vehicle speed is greater than 5 mph. Solenoid is threaded into the left side of the transmission. OPERATION When vehicle speed is less than 5 mph, the PCM provides a ground for the solenoid (energized) and allows shifting. When vehicle speed is greater than 5 mph, the solenoid is deactivated and prevents the transmission from being shifted into reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3860 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3861 Overdrive Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3862 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3865 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3866 Overdrive Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3867 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Pressure Regulating Solenoid: Description and Operation 42RLE Automatic Transmission Solenoid Pressure Control SOLENOID - PRESSURE CONTROL DESCRIPTION The pressure control solenoid (1) is mounted on the top of the valve body, next to the line pressure sensor (2). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The pressure control solenoid (PCS) is a variable force (VFS) style solenoid. A VFS solenoid is an electrohydraulic actuator, combining a solenoid and a regulating valve. The transmission control module varies the current for the PCS, which varies the pressure in the line pressure hydraulic circuit. When the current (duty cycle) of the PCS is low, the pressure in the circuit is higher. At 0 current (0% duty cycle), the pressure is at the maximum value. Conversely, when the current is maximized (100% duty cycle), the pressure in the circuit is at the lowest possible value. Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3873 The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3874 gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3875 Pressure Regulating Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3876 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Pressure Regulating Solenoid: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3879 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Solenoid Pressure Control SOLENOID PRESSURE CONTROL REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3880 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3881 Pressure Regulating Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3882 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3886 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 3887 Solenoid - Brake Transmission Shift Interlock Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shift Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3893 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3894 Shift Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission Valve-Solenoid Switch VALVE-SOLENOID SWITCH DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the L/R-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and 5th (if applicable) gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 3895 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3898 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3899 Shift Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 3900 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition ON voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Page 3904 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift and shift points, depending on the present operating conditions and driver demand. This is possible through control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the Quick Learn Procedure must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Page 3905 By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the Monitors display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE 545RFE SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Page 3906 Part 1 Part 2 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3912 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3917 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3918 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3919 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3920 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3921 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3922 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 3923 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications 42RLE Service Fill ............................................................................................................................... ................................................................ 4 Qt (3.8L) 42RLE Overhaul Fill ......................................... ............................................................................................................................................. 17.6 pts (8.3L) 45RFE/545RFE 2WD Service Fill ............................................................................................. ....................................................................... 11 pts (5.2L) 45RFE/545RFE 4WD Service Fill .......... .......................................................................................................................................................... 13 pts (6.2L) 45RFE/545RFE Overhaul Fill ......................................................................................... ........................................................................ 29-33 pts (14-16L) 48RE Service Fill ......................... .............................................................................................................................................................. .......... 4 Qt (3.8L) 48RE Overhaul Fill ................................................................................................. ................................................................................. 29-33 pts (14-16L) Overhaul Fill - Dry Fill Capacity. Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 3926 Fluid - A/T: Fluid Type Specifications ATF Type ............................................................................................................................................. .......................................................... Mopar ATF+4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed Fluid - A/T: Service and Repair 45RFE 4 Speed/545RFE 5 Speed Fluid Level and Condition Check FLUID AND FILTER DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. FLUID CONTAMINATION Transmission fluid contamination is generally a result of: ^ adding incorrect fluid ^ failure to clean dipstick and fill tube when checking level ^ engine coolant entering the fluid ^ internal failure that generates debris ^ overheat that generates sludge (fluid breakdown) ^ failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transmission has too much fluid, the geartrain churns up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transmission vent where it may be mistaken for a leak. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. The transmission has a dipstick to check oil level. It is located on the right side of the engine. Be sure to wipe all dirt from dipstick handle before removing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 3929 The torque converter fills in both the P (PARK) and N (NEUTRAL) positions. Place the selector lever in P (PARK) to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature (approximately 82°C. or 180°F), the fluid level is correct if it is in the HOT region (crosshatched area) on the oil level indicator. The fluid level will be approximately at the upper COLD hole of the dipstick at 21°C (70°F) fluid temperature. NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Shift the transmission into DRIVE for approximately 2 seconds. 3. Shift the transmission into REVERSE for approximately 2 seconds. 4. Shift the transmission into PARK. 5. Hook up scan tool and select transmission. 6. Select sensors. 7. Read the transmission temperature value. 8. Compare the fluid temperature value with the chart. 9. Adjust transmission fluid level shown on the dipstick according to the Transmission Fluid Temperature Chart. NOTE: After adding any fluid to the transmission, wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. 10. Check transmission for leaks. Fluid and Filter Service FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 3930 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to testing. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (7 ft. lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR ATF +4. Transmission Fill TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4 to transmission: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 3931 a. If only fluid and filter were changed, add 10 pints (5 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled and the torque converter was replaced or drained, add 24 pints (12 quarts) of ATF +4 to transmission. 3. Check the transmission fluid and adjust as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 3932 Fluid - A/T: Service and Repair 42RLE Automatic Transmission Fluid Level Check - 42RLE FLUID AND FILTER CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has two primary causes. 1. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 2. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. FLUID CONTAMINATION Transmission fluid contamination is generally a result of: ^ adding incorrect fluid ^ failure to clean dipstick and fill tube when checking level ^ engine coolant entering the fluid ^ internal failure that generates debris ^ overheat that generates sludge (fluid breakdown) ^ failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. FLUID LEVEL CHECK The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the PARK and NEUTRAL positions. Place the selector lever in PARK to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature ( approximately 82° C or 180°F), the fluid level is correct if it is in the HOT region (crosshatched area) on the oil level indicator. The fluid level should be in COLD region at 21°C (70°F) fluid temperature. Adjust fluid level as necessary Use only Mopar ATF+4, Automatic Transmission Fluid. FLUID LEVEL CHECK USING SCAN TOOL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 3933 NOTE: Engine and Transmission should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Connect scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. 5. Compare the fluid temperature value with the chart. 6. Adjust transmission fluid level shown on the dipstick according to the 42RLE Fluid Temperature Chart. Use only Mopar ATF+4, Automatic Transmission Fluid. 7. Check transmission for leaks. Fluid/Filter Service - 42RLE FLUID/FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF+4, Automatic Transmission Fluid, should be used in the transmission sump. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transmission is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transmission oil pan. NOTE: One of the oil pan bolts (5) has a sealing patch applied from the factory. Separate this bolt for reuse. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 45RFE 4 Speed/545RFE 5 Speed > Page 3934 3. Install a new filter and o-ring on bottom of the valve body and tighten retaining screws to 5 Nm (45 inch lbs.). NOTE: Before installing the oil pan bolt (5) in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits, it will be necessary to replenish the sealing patch on the bolt using Mopar Lock & Seal Adhesive. 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 20 Nm (14.5 ft. lbs.). 5. Pour four quarts of Mopar ATF+4, Automatic Transmission Fluid, through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick. 8. Recheck the fluid level after the transmission has reached normal operating temperature, 82°C (180°F). 9. To prevent dirt from entering transmission, make certain that dipstick is fully seated into the dipstick opening. Transmission Fill - 42RLE TRANSMISSION FILL To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: 1. Remove dipstick and insert clean funnel in transmission fill tube. 2. Add following initial quantity of Mopar ATF +4 to transmission: a. If only fluid and filter were changed, add 3 pints (11/2 quarts) of ATF +4 to transmission. b. If transmission was completely overhauled, torque converter was replaced or drained, and cooler was flushed, add 12 pints (6 quarts) of ATF +4 to transmission. 3. Apply parking brakes. 4. Start and run engine at normal curb idle speed. 5. Apply service brakes, shift transmission through all gear ranges then back to NEUTRAL, set parking brake, and leave engine running at curb idle speed. 6. Remove funnel, insert dipstick and check fluid level. If level is low, add fluid to bring level to MIN mark on dipstick. Check to see if the oil level is equal on both sides of the dipstick. If one side is noticeably higher than the other, the dipstick has picked up some oil from the dipstick tube. Allow the oil to drain down the dipstick tube and recheck. 7. Drive vehicle until transmission fluid is at normal operating temperature. 8. With the engine running at curb idle speed, the gear selector in NEUTRAL, and the parking brake applied, check the transmission fluid level. CAUTION: Do not overfill transmission, fluid foaming and shifting problems can result. 9. Add fluid to bring level up to MAX arrow mark. When fluid level is correct, shut engine off, release park brake, remove funnel, and install dipstick in fill tube Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement Technical Service Bulletin # E16 Date: 051001 Campaign - A/T 545RFE Cooler Return Filter Replacement October, 2005 Dealer Service Instructions for: Customer Satisfaction Notification E16 Transmission Cooler Return Filter Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin # 21-016-05 is cancelled for 2006 vehicles. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2006 (DR) Dodge Ram 1500 2006 (DH) Dodge Ram 2500 2006 (D1) Dodge Ram 3500 2006 (HB) Dodge Durango 2006 (ND) Dodge Dakota 2006 (KJ) Jeep Liberty 2006 (WK) Jeep Grand Cherokee 2006 (XK) Jeep Commander NOTE: This notification applies only to the above vehicles equipped with a 545RFE automatic transmission (sales code DGO) and a transmission built date code from TJ1015 through TJ2315. Many of the vehicles built within this date range were repaired before shipment to dealers and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The transmission on about 17,200 of the above vehicles may experience a delayed engagement when the shifter is placed into gear after the engine has been off for more than 12 hours. Repair The internal transmission cooler return filter must be replaced. Parts Information Special Tool Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3943 The Special Tool is required to perform this recall: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3944 1. Raise vehicle on a hoist. 2. Remove transmission skid plate (if so equipped). 3. Place a drain container with a large opening, under transmission oil pan. 4. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain, and then remove the oil pan. 5. Clean the oil pan and wipe the magnet with a clean dry lint-free cloth. 6. Clean transmission case oil pan surface using a plastic scraper. Caution: Be careful not to scratch the sealing surface. 7. Remove the round transmission cooler filter using an oil filter wrench (special tool 8321). (Figure 1) Remove the filter connector nipple from the transmission if necessary. Discard both parts. 8. Install new cooler return filter to the transmission and tighten the filter to 125 in lbs (14 N.m) (Fig. 1). 9. Apply a 1/8" bead of Mopar ATF-RTV Silicone Adhesive sealant to the transmission oil pan. 10. Install transmission oil pan and tighten oil pan bolts to 105 in lbs (12 N.m). 11. Install transmission skid plate (if so equipped). 12. Pour seven quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening. 13. Start engine and allow it to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position. 14. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to second hole from the tip of the dipstick (full cold transmission). The transmission temperature should be at about 70°F. CAUTION: DO NOT OVERFILL. 15. Recheck the fluid level after the transmission has reached normal operating temperature (180°F.). Adjust fluid level as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Recalls: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3945 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: Customer Interest A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3951 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3952 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3953 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: Customer Interest A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3958 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: All Technical Service Bulletins A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3964 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3965 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3966 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement Technical Service Bulletin # E16 Date: 051001 Campaign - A/T 545RFE Cooler Return Filter Replacement October, 2005 Dealer Service Instructions for: Customer Satisfaction Notification E16 Transmission Cooler Return Filter Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin # 21-016-05 is cancelled for 2006 vehicles. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2006 (DR) Dodge Ram 1500 2006 (DH) Dodge Ram 2500 2006 (D1) Dodge Ram 3500 2006 (HB) Dodge Durango 2006 (ND) Dodge Dakota 2006 (KJ) Jeep Liberty 2006 (WK) Jeep Grand Cherokee 2006 (XK) Jeep Commander NOTE: This notification applies only to the above vehicles equipped with a 545RFE automatic transmission (sales code DGO) and a transmission built date code from TJ1015 through TJ2315. Many of the vehicles built within this date range were repaired before shipment to dealers and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The transmission on about 17,200 of the above vehicles may experience a delayed engagement when the shifter is placed into gear after the engine has been off for more than 12 hours. Repair The internal transmission cooler return filter must be replaced. Parts Information Special Tool Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3971 The Special Tool is required to perform this recall: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3972 1. Raise vehicle on a hoist. 2. Remove transmission skid plate (if so equipped). 3. Place a drain container with a large opening, under transmission oil pan. 4. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain, and then remove the oil pan. 5. Clean the oil pan and wipe the magnet with a clean dry lint-free cloth. 6. Clean transmission case oil pan surface using a plastic scraper. Caution: Be careful not to scratch the sealing surface. 7. Remove the round transmission cooler filter using an oil filter wrench (special tool 8321). (Figure 1) Remove the filter connector nipple from the transmission if necessary. Discard both parts. 8. Install new cooler return filter to the transmission and tighten the filter to 125 in lbs (14 N.m) (Fig. 1). 9. Apply a 1/8" bead of Mopar ATF-RTV Silicone Adhesive sealant to the transmission oil pan. 10. Install transmission oil pan and tighten oil pan bolts to 105 in lbs (12 N.m). 11. Install transmission skid plate (if so equipped). 12. Pour seven quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening. 13. Start engine and allow it to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position. 14. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to second hole from the tip of the dipstick (full cold transmission). The transmission temperature should be at about 70°F. CAUTION: DO NOT OVERFILL. 15. Recheck the fluid level after the transmission has reached normal operating temperature (180°F.). Adjust fluid level as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3973 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3978 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set Fluid Filter - A/T: All Technical Service Bulletins A/T - Delayed Shift Engagement/Related DTC's Set NUMBER: 21-007-06 GROUP: Transmission DATE: April 07, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-016-05, DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: RFE Transmission Filters - Delayed Engagement And Related Transmission DTC'S OVERVIEW: This bulletin involves verifying the build date of the transmission, and if necessary, the replacement of both the cooler return and sump filters in the transmission. MODELS: 2005 - 2006 (DR) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty / Cherokee 2005 - 2006 (ND) Dakota 2005 - 2006 (WK / WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with the a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively) having a specific transmission build date code (see the below DIAGNOSIS section for further details). SYMPTOM/CONDITION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may also experience a MIL illumination. Investigation may determine that the MIL is due to one or more of the following Diagnostic Trouble Codes (DIG's): P0868 - Line Pressure Low. This DIG will be the most frequently occurring DTC for the delayed shift condition. P0944 - Loss Of Hydraulic Pump Prime. P0731 - Gear Ratio Error In 1st. P0736 - Gear Ratio Error In Reverse. P0841 - LR Pressure Switch Rationality. P0876 - UD Pressure Switch Rationality. The delayed engagement and MIL condition (DTC's) may be caused by a suspect transmission cooler return filter with a part number of 04799662AB. A suspect 04799662AB cooler return filter may cause the transmission sump filter to split at its plastic-to-metal crimp. If the transmission sump filter becomes split at the crimp, then one or more of the above DTC's may also occur. DIAGNOSIS: 1. Turn the ignition to the "OFF" position. 2. Raise the vehicle on a suitable lift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3984 3. Inspect for the transmission build date (Julian date) (Fig. 1). The transmission build date can be determined by inspection of the 20 digit transmission identification number (DDDYxxxxxPpartnumber). The transmission identification number is stamped on the left side (driver side) of the transmission oil pan flange. The first four (4) digits of the transmission identification number are the transmission build date, in Julian date format. An example of a transmission identification number would be 101510492P52119684AA. The first three digits ( 101 ) of the identification number equal the day of the year, in this case 101 equals April 11. The fourth digit ( 5 ) of the identification number equals the calendar year, in this case 5 equals 2005. So 1015 equals April 11, 2005. 4. Determine if the vehicle's transmission was built on or between one of the two sets of Julian date build ranges listed below: a. Julian date 0425 (February 11, 2005) to Julian date 0455 (February 15, 2005). 0425 to 0455. b. Julian date 1015 (April 11, 2005) to Julian date 2345 (August 22, 2005). 1015 to 2345. 5. If the vehicle has the above condition, and if the transmission Julian build date is on or between the range of dates listed above, perform the Repair Procedure. NOTE: Both the transmission cooler return filter and the transmission sump filter MUST BE replaced at the same time. PARTS REQUIRED: NOTE: DO NOT use a replacement cooler return filter with a part number of 04799662AB. This filter is suspect of causing the above condition. The cooler Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3985 return filter part number is stenciled on the side of the filter's metal case. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: All cooler return filters with the "AB" suffix (04799662AB) are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level), and a new sump filter. NOTE: BOTH the sump oil filter and the cooler return filter MUST BE replaced in the transmission at the same time. Do not replace one filter without also replacing the other filter. NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to4ilter connection to 18.6 Nm (165 in.lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in.lbs.) Use the procedures outlined in TechCONNECT(R) (Service Information Tab / 21 - Transmission Transaxle / Automatic - 45RFE 545RFE / Fluid / Standard Procedure / Fluid and Filter Replacement) to replace BOTH the transmission cooler return filter and the transmission sump oil filter. NOTE: Always install the sump filter seal to the bottom of the transmission oil pump first, then install the sump filter to the oil pump and previously installed seal. DO NOT install the sump filter seal to the sump filter and then attempt to install both to the oil pump. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-007-06 > Apr > 06 > A/T - Delayed Shift Engagement/Related DTC's Set > Page 3986 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; Fluid Filter - A/T: All Technical Service Bulletins A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; NUMBER: 21-015-05 GROUP: Transmission DATE: September 01, 2005 SUBJECT: 45RFE / 545RFE Trans - Delayed Engagement Due To Cooler Return Filter Replacement OVERVIEW: This bulletin involves a transmission delayed shift condition that may occur following the replacement of the internal cooler return filter. MODELS: 2000 - 2004 (AN) Dakota 2000 - 2003 (DN) Durango 2003 - 2006 (DR) Ram Truck 2004 - 2006 (HB) Durango 2002 - 2006 (KJ) Liberty 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - 2006 (WK/WH) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a 45RFE or a 545RFE automatic transmission (sales code DG4 or DGQ respectively). DISCUSSION: The customer may experience an initial delayed shift engagement following an extended off (not running) period of time, generally after being parked overnight. The initial shift engagement may feel like a delay or slip when a transmission gear (reverse or drive) is first selected after engine start. The customer may not have experienced the delayed shift engagement until after the transmission has been serviced, where the cooler return filter was replaced during the service and/or repair. The condition is not detrimental to the transmission but may cause concern with the customer. The above condition may be caused by a suspect cooler return filter a part number of 04799662AB. This "AB" suffix / level filter may allow transmission fluid to drain back out of the torque converter. The drain back condition may occur over a period time when the engine (and transmission) are not running. With less fluid in the torque converter a delay in gear engagement may occur at engine start up while the torque converter fills to its proper fluid level. All 04799662AB cooler return filters with the "AB" suffix are suspect. The above condition may be corrected by replacing a suspect "AB" filter with a new cooler return filter whose part number is 04799662 (with no suffix or with a suffix that is other than the "AB" level). NOTE: The cooler return filter, p/n 04799662, will not be available until September 09, 2005. The filter part number is stenciled on the side of the filter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > 21-015-05 > Sep > 05 > A/T - 45RFE/545RFE Delayed Engagement After Filter R&R; > Page 3991 NOTE: A replacement 04799662 cooler return filter may come packaged with a separate threaded adapter stud. The threaded adapter stud is used to attach the cooler return filter to the transmission. Inspect the stud and note end without threads. Install the stud end without the threads into the cooler return filter and tighten the stud-to-filter connection to 18.6 Nm (165 in. lbs.). Once the threaded adapter stud has been installed to the cooler return filter, install the assembled cooler return filter to the transmission and tighten the filter to 14.1 Nm (125 in. lbs.) POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement Technical Service Bulletin # E16 Date: 051001 Campaign - A/T 545RFE Cooler Return Filter Replacement October, 2005 Dealer Service Instructions for: Customer Satisfaction Notification E16 Transmission Cooler Return Filter Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Service Bulletin # 21-016-05 is cancelled for 2006 vehicles. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2006 (DR) Dodge Ram 1500 2006 (DH) Dodge Ram 2500 2006 (D1) Dodge Ram 3500 2006 (HB) Dodge Durango 2006 (ND) Dodge Dakota 2006 (KJ) Jeep Liberty 2006 (WK) Jeep Grand Cherokee 2006 (XK) Jeep Commander NOTE: This notification applies only to the above vehicles equipped with a 545RFE automatic transmission (sales code DGO) and a transmission built date code from TJ1015 through TJ2315. Many of the vehicles built within this date range were repaired before shipment to dealers and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The transmission on about 17,200 of the above vehicles may experience a delayed engagement when the shifter is placed into gear after the engine has been off for more than 12 hours. Repair The internal transmission cooler return filter must be replaced. Parts Information Special Tool Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3997 The Special Tool is required to perform this recall: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3998 1. Raise vehicle on a hoist. 2. Remove transmission skid plate (if so equipped). 3. Place a drain container with a large opening, under transmission oil pan. 4. Loosen pan bolts and using a thin wide blade putty knife, separate the pan from the transmission housing at one corner to break it loose. Allow the fluid to drain, and then remove the oil pan. 5. Clean the oil pan and wipe the magnet with a clean dry lint-free cloth. 6. Clean transmission case oil pan surface using a plastic scraper. Caution: Be careful not to scratch the sealing surface. 7. Remove the round transmission cooler filter using an oil filter wrench (special tool 8321). (Figure 1) Remove the filter connector nipple from the transmission if necessary. Discard both parts. 8. Install new cooler return filter to the transmission and tighten the filter to 125 in lbs (14 N.m) (Fig. 1). 9. Apply a 1/8" bead of Mopar ATF-RTV Silicone Adhesive sealant to the transmission oil pan. 10. Install transmission oil pan and tighten oil pan bolts to 105 in lbs (12 N.m). 11. Install transmission skid plate (if so equipped). 12. Pour seven quarts of Mopar ATF+4 Automatic Transmission Fluid into the fill tube opening. 13. Start engine and allow it to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the neutral position. 14. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to second hole from the tip of the dipstick (full cold transmission). The transmission temperature should be at about 70°F. CAUTION: DO NOT OVERFILL. 15. Recheck the fluid level after the transmission has reached normal operating temperature (180°F.). Adjust fluid level as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Filter - A/T: > E16 > Oct > 05 > Campaign - A/T 545RFE Cooler Return Filter Replacement > Page 3999 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 42RLE 4 Speed Fluid Filter - A/T: Service and Repair 42RLE 4 Speed FLUID/FILTER SERVICE NOTE: Only fluids of the type labeled Mopar ATF+4, Automatic Transmission Fluid, should be used in the transmission sump. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transmission is disassembled for any reason, the fluid and filter should be changed. 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transmission oil pan. NOTE: One of the oil pan bolts (5) has a sealing patch applied from the factory. Separate this bolt for reuse. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and o-ring on bottom of the valve body and tighten retaining screws to 5 Nm (45 inch lbs.). NOTE: Before installing the oil pan bolt (5) in the bolt hole located between the torque converter clutch on and U/D clutch pressure tap circuits, it will be necessary to replenish the sealing patch on the bolt using Mopar Lock & Seal Adhesive. 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 20 Nm (14.5 ft. lbs.). 5. Pour four quarts of Mopar ATF+4, Automatic Transmission Fluid, through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transmission fluid level and add an appropriate amount to bring the transmission fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick. 8. Recheck the fluid level after the transmission has reached normal operating temperature, 82°C (180°F). 9. To prevent dirt from entering transmission, make certain that dipstick is fully seated into the dipstick opening. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 42RLE 4 Speed > Page 4002 Fluid Filter - A/T: Service and Repair 45RFE 4 Speed/545RFE 5 Speed FLUID AND FILTER REPLACEMENT REMOVAL 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove bolts holding front and sides of pan to transmission. 4. Loosen bolts holding rear of pan to transmission. 5. Slowly separate front of pan away from transmission allowing the fluid to drain into drain pan. 6. Hold up pan and remove remaining bolts holding pan to transmission. 7. While holding pan level, lower pan away from transmission. 8. Pour remaining fluid in pan into drain pan. 9. Remove the screw holding the primary oil filter (1) to valve body. 10. Separate filter from valve body and oil pump and pour fluid in filter into drain pan. 11. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove and discard the oil filter seal from the bottom of the oil pump. If the seal is installed correctly and is in good condition, it can be reused. 12. If replacing the cooler return filter (2), use Oil Filter Wrench 8321 to remove the filter from the transmission. 13. Dispose of used trans fluid and filter(s) properly. INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and pan are contaminated with excessive amounts of debris, refer to testing. CLEANING 1. Using a suitable solvent, clean pan and magnet. 2. Using a suitable gasket scraper, clean original sealing material from surface of transmission case and the transmission pan. INSTALLATION CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with a suitable tool (appropriately sized drift or socket, the butt end of a hammer, or other suitable tool). 2. Place replacement filter in position on valve body and into the oil pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 42RLE 4 Speed > Page 4003 3. Install screw to hold the primary oil filter (1) to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 4. Install new cooler return filter (2) onto the transmission, if necessary. Torque the filter to 9.5 Nm (7 ft. lbs.). 5. Place bead of Mopar RTV sealant onto the transmission case sealing surface. 6. Place pan in position on transmission. 7. Install bolts to hold pan to transmission. Tighten bolts to 12 Nm (105 inch lbs.) torque. 8. Lower vehicle and fill transmission with MOPAR ATF +4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair Fluid Line/Hose: Service and Repair TRANSMISSION COOLER LINE QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove dust cap by pulling it straight back off of quick connect fitting. 2. Place disconnect tool Special Tool 8875A onto transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide disconnect tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the disconnect tool 600 to expand the retaining clip. 5. While holding the disconnect tool against the quick connect fitting, pull back on the transmission cooler line to remove. CONNECT Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4007 1. Align transmission cooler line with quick connect fitting while pushing straight into the fitting. 2. Push in on transmission cooler line until a click is heard or felt. 3. Slide dust cap down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. Dust cap will only snap over quick connect fitting when the transmission cooler line is properly installed. NOTE: If dust cap will not snap into place, repeat assembly step 2. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 42RLE 4 Speed Fluid Pan: Specifications 42RLE 4 Speed Bolt, Oil Pan-to-Case ........................................................................................................................... .................................................. 20 Nm (14.5 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 42RLE 4 Speed > Page 4012 Fluid Pan: Specifications 45RFE 4 Speed/545RFE 5 Speed Bolt, oil pan .......................................................................................................................................... ............................................. 1-2 Nm (105 inch lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4016 Sensor - Line Pressure (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Description and Operation 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4019 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE DESCRIPTION The line pressure sensor (2) is mounted on the top of the valve body, next to the pressure control solenoid 0). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4020 Fluid Pressure Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Line Pressure SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4021 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4024 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4025 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4026 Fluid Pressure Sensor/Switch: Service and Repair 45RFE/545RFE Automatic Transmission Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4027 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Sensor-Line Pressure SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pres sure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4028 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair Fluid Pump: Service and Repair OIL PUMP VOLUME CHECK Measuring the oil pump output volume will determine if sufficient oil flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that the transmission fluid is at the proper level. If necessary, fill the transmission to the proper level with Mopar ATF +4, Automatic Transmission Fluid. 1. Disconnect the To cooler line at the cooler inlet and place a collecting container under the disconnected line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Run the engine at 1800 rpm, with the shift selector in neutral. Verify that the transmission fluid temperature is below 104.5°C (220°F) for this test. 3. If one quart of transmission fluid is collected in the container in 30 seconds or less, oil pump flow volume is within acceptable limits. If fluid flow is intermittent, or it takes more than 30 seconds to collect one quart of fluid, refer to the Hydraulic Pressure tests. 4. Reconnect the To cooler line to the transmission cooler inlet. 5. Refill the transmission to proper level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. The overdrive off indicator gives an indication to the vehicle operator when the overdrive off feature has been selected using the tow/haul switch, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the overdrive off indicator for the following reasons: - Overdrive Off Lamp-On Message - Each time the cluster receives an overdrive off lamp-on message from the PCM indicating that the overdrive off feature has been selected, the overdrive off indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive off lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive off lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the overdrive off indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 4037 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text "TOW/HAUL" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the tow/haul feature has been selected using the tow/haul switch, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the transmission temperature sensor, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type and model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Controller Area Network (CAN) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the Transmission Range Sensor (TRS), then sends the proper gear selector indicator position messages to the instrument cluster. On vehicles without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, refer to testing. For further diagnosis of the TRS on vehicles without a TCM, refer to Transmission and Drivetrain/Automatic Transmission/ Transaxle. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4049 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4050 Overdrive Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4051 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4054 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4055 Overdrive Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Assembly, A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4056 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. The overdrive off indicator gives an indication to the vehicle operator when the overdrive off feature has been selected using the tow/haul switch, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the overdrive off indicator for the following reasons: - Overdrive Off Lamp-On Message - Each time the cluster receives an overdrive off lamp-on message from the PCM indicating that the overdrive off feature has been selected, the overdrive off indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive off lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive off lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the overdrive off indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 4061 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text "TOW/HAUL" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the tow/haul feature has been selected using the tow/haul switch, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 4065 Switch - Tow/Haul Overdrive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Switch: Description and Operation 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4068 Overdrive Switch: Description and Operation 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4071 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4072 Overdrive Switch: Service and Repair 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4073 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Pressure Regulating Solenoid: Description and Operation 42RLE Automatic Transmission Solenoid Pressure Control SOLENOID - PRESSURE CONTROL DESCRIPTION The pressure control solenoid (1) is mounted on the top of the valve body, next to the line pressure sensor (2). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The pressure control solenoid (PCS) is a variable force (VFS) style solenoid. A VFS solenoid is an electrohydraulic actuator, combining a solenoid and a regulating valve. The transmission control module varies the current for the PCS, which varies the pressure in the line pressure hydraulic circuit. When the current (duty cycle) of the PCS is low, the pressure in the circuit is higher. At 0 current (0% duty cycle), the pressure is at the maximum value. Conversely, when the current is maximized (100% duty cycle), the pressure in the circuit is at the lowest possible value. Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4079 The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4080 gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4081 Pressure Regulating Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4082 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Pressure Regulating Solenoid: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4085 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Solenoid Pressure Control SOLENOID PRESSURE CONTROL REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4086 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4087 Pressure Regulating Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4088 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition ON voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4093 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift and shift points, depending on the present operating conditions and driver demand. This is possible through control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the Quick Learn Procedure must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4094 By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the Monitors display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE 545RFE SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4095 Part 1 Part 2 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4100 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4101 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4102 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4103 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4104 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4105 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4106 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4107 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4108 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4109 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4110 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4111 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4112 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4113 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4114 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4115 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4116 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4117 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4118 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4119 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description Transmission Control System Relay: Description and Operation Description DESCRIPTION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description > Page 4122 Transmission Control System Relay: Description and Operation Operation OPERATION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 42RLE Automatic Transmission Seals and Gaskets: Service and Repair 42RLE Automatic Transmission Seal Extension Housing SEAL EXTENSION HOUSING REMOVAL 1. Raise vehicle. 2. Mark propeller shaft and axle yoke, or companion flange, for alignment reference. 3. Disconnect and remove propeller shaft. 4. Remove old seal with a generic seal remover (1) from overdrive extension housing. INSTALLATION 1. Place seal in position on overdrive housing. 2. Drive seal into overdrive housing with Seal Installer C3995A (1). 3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke. Seal Oil Pump SEAL OIL PUMP REMOVAL 1. Remove the transmission from the vehicle. 2. Remove the torque converter from the transmission bellhousing. 3. Use a screw mounted in a slide hammer to remove oil pump seal. INSTALLATION 1. Clean and inspect oil pump seal seat. Then install seal using Seal Installer C4193A. 2. Clean and inspect torque converter hub. If nicks, scratches or hub wear are found, torque converter replacement will be required. CAUTION: If the torque converter is being replaced, apply a light coating of grease to the crankshaft pilot hole. Also inspect the engine drive plate for cracks. If any cracks are found replace the drive plate. Do not attempt to repair a cracked drive plate. Always use new torque converter to drive plate bolts. 3. Apply a light film of transmission oil to the torque converter hub and oil seal lips. Then install torque converter into transmission. Be sure that the hub lugs mesh with the front pump lugs when installing. 4. Reinstall the transmission into the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 42RLE Automatic Transmission > Page 4127 Seals and Gaskets: Service and Repair 45RFE/545RFE Automatic Transmission SEAL-OIL PUMP FRONT REMOVAL 1. Remove transmission from the vehicle. 2. Remove the torque converter from the transmission. 3. Using a screw mounted in a slide hammer, remove the oil pump front seal. INSTALLATION 1. Clean seal bore of the oil pump of any residue or particles from the original seal. 2. Install new oil seal in the oil pump housing using Seal Installer C3860A (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4132 Sensor - Line Pressure (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Description and Operation 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4135 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE DESCRIPTION The line pressure sensor (2) is mounted on the top of the valve body, next to the pressure control solenoid 0). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4136 Fluid Pressure Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Line Pressure SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4137 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4140 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4141 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4142 Fluid Pressure Sensor/Switch: Service and Repair 45RFE/545RFE Automatic Transmission Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4143 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Sensor-Line Pressure SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pres sure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4144 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4148 Switch - Tow/Haul Overdrive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Switch: Description and Operation 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4151 Overdrive Switch: Description and Operation 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4154 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4155 Overdrive Switch: Service and Repair 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4156 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Shift Interlock Switch > Component Information > Locations > Page 4160 Switch - Clutch Interlock (M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4165 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4166 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4167 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4170 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4171 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4172 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4176 Transmission Speed Sensor: Diagrams Sensor - Input Speed (RFE/RLE) Sensor - Output Speed (RFE/RLE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Speed Sensor: Description and Operation 42RLE Automatic Transmission Sensor Output Speed SENSOR OUTPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor Input Speed SENSOR INPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4179 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4180 Transmission Speed Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Speed Sensor: Service and Repair 42RLE Automatic Transmission Sensor Input Speed SENSOR INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor (1) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor Output Speed SENSOR OUTPUT SPEED REMOVAL 1. Raise vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4183 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor(2). NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor (2) from the transmission case. INSTALLATION 1. Install the output speed sensor (2) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4184 Transmission Speed Sensor: Service and Repair 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the trans mission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor-Output Speed SENSOR-OUTPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4185 3. Remove the wiring connector from the output speed sensor(1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Temperature Sensor/Switch: Description and Operation 42RLE Automatic Transmission Sensor Transmission Range SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Sensor Transmission Temperature SENSOR TRANSMISSION TEMPERATURE DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4190 The transmission temperature sensor (2) is located in the transmission range sensor (1) and communicates transmission sump temperature to the TCM. OPERATION The transmission range sensor (TRS) has an integrated thermistor that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The TCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4191 Transmission Temperature Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Temperature SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4192 Transmission Temperature Sensor/Switch: Service and Repair SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4193 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4198 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4199 Solenoid - Brake Transmission Shift Interlock Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Switch > Component Information > Locations > Page 4203 Switch - Clutch Interlock (M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shift Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4209 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4210 Shift Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission Valve-Solenoid Switch VALVE-SOLENOID SWITCH DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the L/R-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and 5th (if applicable) gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4211 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4214 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4215 Shift Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4216 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shifter A/T: Description and Operation 42RLE Automatic Transmission MECHANISM SHIFT DESCRIPTION The gear shift mechanism provides six shift positions which are: ^ Park (P) ^ Reverse (R) ^ Neutral (N) ^ Drive (D) ^ Manual second (2) ^ Manual low (1) OPERATION MANUAL LOW (1) range provides FIRST gear only Overrun braking is also provided in this range. MANUAL SECOND (2) range provides FIRST and SECOND gear only. DRIVE range provides FIRST, SECOND, THIRD and OVERDRIVE FOURTH gear ranges. The shift into OVERDRIVE FOURTH gear range occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The FOURTH gear upshift occurs automatically when the overdrive selector switch is in the ON position. An upshift to FOURTH gear may not occur or may be delayed in some of the possible shift schedules. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4221 Shifter A/T: Description and Operation 45RFE/545RFE Automatic Transmission MECHANISM-SHIFT DESCRIPTION The gear shift mechanism provides six shift positions which are: ^ Park (P) ^ Reverse (R) ^ Neutral (N) ^ Drive (D) ^ Manual second (2) ^ Manual low (1) OPERATION MANUAL LOW (1) range provides first gear only Overrun braking is also provided in this range. MANUAL SECOND (2) range provides first and second gear only DRIVE range provides FIRST, SECOND, THIRD, OVERDRIVE FOURTH, and OVERDRIVE FIFTH (if applicable) gear ranges. The shift into OVERDRIVE FOURTH and FIFTH (if applicable) gear ranges occurs only after the transmission has completed the shift into D THIRD gear range. No further movement of the shift mechanism is required to complete the 3-4 or 4-5 (if applicable) shifts. The FOURTH and FIFTH (if applicable) gear upshifts occur automatically when the overdrive selector switch is in the ON position. No upshift to FOURTH or FIFTH (if applicable) gears will occur if any of the following are true: ^ The transmission fluid temperature is below 10°C (50°F) or above 121°C (250°F). ^ The shift to THIRD is not yet complete. ^ Vehicle speed is too low for the 3-4 or 4-5 (if applicable) shifts to occur. Upshifts into FOURTH or FIFTH (if applicable) will be delayed when the transmission fluid temperature is below 4.5°C (40°F) or above 115.5°C (240°F). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission Shift Cable: Testing and Inspection 42RLE Automatic Transmission GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position-Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position-Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position-Normal position. Engine starts must be possible. d. NEUTRAL position-Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > 42RLE Automatic Transmission > Page 4227 Shift Cable: Testing and Inspection 45RFE/545RFE Automatic Transmission CABLE-GEARSHIFT 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position-Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position-Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position-Normal position. Engine starts must be possible. d. NEUTRAL position-Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 42RLE Automatic Transmission Shift Cable: Adjustments 42RLE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 42RLE Automatic Transmission > Page 4230 Shift Cable: Adjustments 45RFE/545RFE Automatic Transmission ADJUSTMENTS - GEARSHIFT CABLE Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Cable: Service and Repair 42RLE Automatic Transmission CABLE GEARSHIFT REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4233 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4234 Shift Cable: Service and Repair 45RFE/545RFE Automatic Transmission REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (3) and pull cable adjuster out of mounting bracket. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4235 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent (rearmost) position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket and secure the cable by snapping the cable retaining ears into the transmission bracket and snapping the cable eyelet on the manual shift lever ball stud. 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable and BTSI mechanism as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the transmission temperature sensor, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission Torque Converter: Description and Operation 42RLE Automatic Transmission CONVERTER TORQUE DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (4), an overrunning clutch, an impeller (2) and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4243 The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4244 The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4245 The stator contains an overrunning clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the overrunning clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller (3) and turbine (5) were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) with friction material (7) was added to the turbine assembly (5) to provide this mechanical lockup. In order to reduce heat buildup in the transmission and buffer the powertrain against tensional vibrations, the TCM can duty cycle the L/R-CC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: ^ Shift lever position ^ Current gear range ^ Transmission fluid temperature ^ Engine coolant temperature ^ Input speed ^ Throttle angle Engine speed OPERATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4246 The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stature's overrunning clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lockup is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4247 In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in second, third, fourth, and fifth (if applicable) gear ranges depending on overdrive control switch position. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to fourth gear. If the control switch is in the OFF position, the clutch will engage after the shift to third gear. The TCM controls the torque converter by way of internal logic software. The programming of the software provides the TCM with control over the L/RCC Solenoid. There are four output logic states that can be applied as follows: ^ No EMCC ^ Partial EMCC ^ Full EMCC ^ Gradual to no EMCC NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL-TO-NO EMCC This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid-throttle by decreasing the L/R Solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4248 Torque Converter: Description and Operation 45RFE/545RFE Automatic Transmission CONVERTER-TORQUE DESCRIPTION The torque converter is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine (1), a stator (2), an overrunning clutch, an impeller (5), and an electronically applied converter clutch (6). The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub (3) drives the transmission oil (fluid) pump and contains an o-ring seal (4) to better control oil flow. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. IMPELLER IMPELLER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4249 The impeller is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving members of the system. TURBINE TURBINE The turbine is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4250 The stator assembly is mounted on a stationary shaft which is an integral part of the oil pump. The stator (1) is located between the impeller (2) and the turbine (4) within the torque converter case. The stator contains an overrunning clutch (1-4), which allows the stator to rotate only in a clockwise direction. When the stator is locked against the overrunning clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shockfree power transfer, it is natural for all fluid couplings to slip. If the impeller (3) and turbine (5) were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston (6) with friction material (7) was added to the turbine assembly (5) to provide this mechanical lockup. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4251 In order to reduce heat buildup in the transmission and buffer the powertrain against torsional vibrations, the TCM can duty cycle the L/RCC Solenoid to achieve a smooth application of the torque converter clutch. This function, referred to as Electronically Modulated Converter Clutch (EMCC) can occur at various times depending on the following variables: ^ Shift lever position ^ Current gear range ^ Transmission fluid temperature ^ Engine coolant temperature ^ Input speed ^ Throttle angle Engine speed OPERATION Torque Converter Fluid Operation - Typical The converter impeller (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's overrunning clutch to its shaft. Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lockup is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4252 Stator Operation In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston and friction material to the front cover, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The clutch can be engaged in second, third, fourth, and fifth (if applicable) gear ranges depending on overdrive control switch position. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift to fourth gear. If the control switch is in the OFF position, the clutch will engage after the shift to third gear. The TCM controls the torque converter by way of internal logic software. The programming of the software provides the TCM with control over the L/R-CC Solenoid. There are four output logic states that can be applied as follows: ^ No EMCC ^ Partial EMCC ^ Full EMCC ^ Gradual-to-no EMCC NO EMCC Under No EMCC conditions, the L/R Solenoid is OFF. There are several conditions that can result in NO EMCC operations. No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions. PARTIAL EMCC Partial EMCC operation modulates the L/R Solenoid (duty cycle) to obtain partial torque converter clutch application. Partial EMCC operation is maintained until Full EMCC is called for and actuated. During Partial EMCC some slip does occur. Partial EMCC will usually occur at low speeds, low load and light throttle situations. FULL EMCC During Full EMCC operation, the TCM increases the L/R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed relative to engine rpm. GRADUAL-TO-NO EMCC This operation is to soften the change from Full or Partial EMCC to No EMCC. This is done at mid-throttle by decreasing the L/R Solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RLE Automatic Transmission Torque Converter: Service and Repair 42RLE Automatic Transmission CONVERTER TORQUE REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION NOTE: Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4255 Torque Converter: Service and Repair 45RFE/545RFE Automatic Transmission CONVERTER-TORQUE REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION NOTE: Check converter hub and drive flats for sharp edges, burrs, scratches, or nicks. Polish the hub and flats with 320/400 grit paper or crocus cloth if necessary. Verify that the converter hub o-ring is properly installed and is free from debris. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or converter hub o-ring while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale (1) and straightedge (2). Surface of converter lugs should be at least 13 mm (1/2 inch) to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4260 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4261 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4262 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4263 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4264 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4265 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4266 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4267 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4268 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4269 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4270 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4271 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4272 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4275 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4276 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4277 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4278 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4279 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description Transmission Control System Relay: Description and Operation Description DESCRIPTION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description > Page 4282 Transmission Control System Relay: Description and Operation Operation OPERATION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation Transmission Cooler: Description and Operation COOLER-TRANSMISSION OIL DESCRIPTION ALL VEHICLES An air-to-oil transmission oil cooler is standard on all engine packages. The transmission oil cooler is mounted to the front of the radiator above the power steering cooler. 5.9L DIESEL All diesel models equipped with an automatic transmission are equipped with both a main water-to-oil cooler and a separate air-to-oil cooler. Both coolers are supplied as standard equipment on diesel engine powered models when equipped with an automatic transmission. The main water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Page 4286 The air-to-oil cooler is located in front of the radiator. OPERATION GAS ENGINES Transmission oil is routed through the cooler where heat is removed from the transmission oil before returning to the transmission. 5.9L DIESEL ENGINE The transmission oil is routed through the main cooler first, then the auxiliary cooler where additional heat is removed from the transmission oil before returning to the transmission. The auxiliary cooler has an internal thermostat that controls fluid flow through the cooler. When the transmission fluid is cold (less then operating temperature), the fluid is routed through the cooler bypass. When the transmission fluid reaches operating temperatures and above, the thermostat closes off the bypass allowing fluid flow through the cooler. The thermostat is serviceable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation > Page 4287 Transmission Cooler: Service and Repair COOLER-TRANSMISSION OIL REMOVAL 5.7L ENGINE 1. Place a drain pan under the oil cooler lines. 2. Disconnect the transmission oil cooler line quickconnect fitting at the cooler outlet using the quick connect release tool 6935. Plug the cooler lines to prevent oil leakage. 3. Unsnap the transmission cooler tubes from the radiator tank clips. 4. Remove the bolt attaching the transmission cooler to the radiator. 5. Remove oil cooler from the vehicle. Take care not to damage the radiator core or transmission cooler tubes. INSTALLATION 1. Position the transmission cooler tubes to the front of the radiator by sliding brackets into slots on radiator inlet tank. 2. Snap the transmission cooler tubes into the clips on the side of the radiator tank. 3. Install the transmission cooler attaching bolt. Tighten the bolt to 16 Nm (140 inch lbs.). 4. Inspect the quick connect fittings for debris and install the quick connect fitting on the cooler tube until an audible click is heard. Pull apart the connection to verify proper installation and install the secondary latches. 5. Start the engine and check all fittings for leaks. 6. Check the fluid level in the automatic transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type and model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Controller Area Network (CAN) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the Transmission Range Sensor (TRS), then sends the proper gear selector indicator position messages to the instrument cluster. On vehicles without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, refer to testing. For further diagnosis of the TRS on vehicles without a TCM, refer to Transmission and Drivetrain/Automatic Transmission/ Transaxle. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4295 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4296 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4297 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4300 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4301 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4302 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4306 Transmission Speed Sensor: Diagrams Sensor - Input Speed (RFE/RLE) Sensor - Output Speed (RFE/RLE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Speed Sensor: Description and Operation 42RLE Automatic Transmission Sensor Output Speed SENSOR OUTPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor Input Speed SENSOR INPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4309 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4310 Transmission Speed Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Speed Sensor: Service and Repair 42RLE Automatic Transmission Sensor Input Speed SENSOR INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor (1) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor Output Speed SENSOR OUTPUT SPEED REMOVAL 1. Raise vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4313 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor(2). NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor (2) from the transmission case. INSTALLATION 1. Install the output speed sensor (2) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4314 Transmission Speed Sensor: Service and Repair 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the trans mission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor-Output Speed SENSOR-OUTPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4315 3. Remove the wiring connector from the output speed sensor(1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Temperature Sensor/Switch: Description and Operation 42RLE Automatic Transmission Sensor Transmission Range SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Sensor Transmission Temperature SENSOR TRANSMISSION TEMPERATURE DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4320 The transmission temperature sensor (2) is located in the transmission range sensor (1) and communicates transmission sump temperature to the TCM. OPERATION The transmission range sensor (TRS) has an integrated thermistor that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The TCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4321 Transmission Temperature Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Temperature SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4322 Transmission Temperature Sensor/Switch: Service and Repair SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4323 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Valve Body: Description and Operation 42RLE Automatic Transmission BODY VALVE DESCRIPTION The valve body assembly consists of a cast aluminum valve body (5), separator plate (4), and transfer plate (3). The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, solenoid/pressure switch assembly, and frictional clutches. Also mounted to the valve body assembly are the solenoid/pressure switch assembly and the transmission range sensor (2). Valve Body - Exploded The valves contained within the valve body (1) include the following: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4328 ^ Regulator valve (8) ^ Solenoid switch valve (7) ^ Manual valve (5) ^ Converter clutch switch valve (6) ^ Converter clutch control valve (4) ^ Torque converter regulator valve (2) ^ Low/Reverse switch valve (3) In addition, the valve body also contains the thermal valve, #2, 3, 4 & 5 check balls and the 2/4 accumulator assembly. OPERATION THERMAL VALVE The thermal valve (1) is a bimetallic shudder valve that helps control the venting rate of oil pressure in the underdrive clutch passage during release of the clutch. When the oil temperature is approximately 20 degrees Fahrenheit or less, the valve is fully open to assist in venting oil past the U1 orifice (2). At temperatures above 20 degrees, the valve starts to close and becomes fully closed at approximately 140 degrees. The thermal valve is located in the transfer plate of the valve body. REGULATOR VALVE The regulator valve (9) controls hydraulic pressure in the transmission. It receives unregulated pressure from the pump (6), which works against spring tension (8) to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4329 SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid (4). In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves (7). MANUAL VALVE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4330 The manual valve (4) is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve (10) is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve (5) is fed to the torque converter regulator valve (8). The pressure is then directed to the converter clutch switch valve (10) and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. CONVERTER CLUTCH CONTROL VALVE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4331 The converter clutch control valve (5) controls the back (on) side of the torque converter clutch (1). When the controller energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve (5) and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under these operating conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4332 Valve Body: Description and Operation 45RFE/545RFE Automatic Transmission BODY-VALVE DESCRIPTION Valve Body Components The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body contains the following components: ^ Solenoid switch valve ^ Manual valve ^ Low/reverse switch valve ^ 5 Accumulators ^ 7 check balls OPERATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4333 NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. SOLENOID SWITCH VALVE The Solenoid Switch Valve (SSV) controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. The Solenoid Switch Valve controls line pressure from the LRTCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and fifth gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. MANUAL VALVE The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually operated by the driver with a lever located on the top of the valve body. The valve is connected mechanically by a cable to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (2) that engages the roostercomb of the TRS selector plate (1) LOW/REVERSE SWITCH VALVE The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Valve Body: Service and Repair 42RLE Automatic Transmission Removal BODY VALVE REMOVAL NOTE: If valve body is being reconditioned or replaced, it is necessary to perform the Quick Learn Procedure. 1. Disconnect the transmission range sensor (5) and solenoid/pressure switch assembly wiring connectors. 2. Disconnect the variable line pressure connector (4), if equipped. 3. Disconnect the shift cable from the shift lever (at the transmission). 4. Move the manual shift lever clockwise as far as it will go. This should be one position past the L position. Then remove the manual shift lever. NOTE: One of the oil pan bolts has a sealing patch applied from the factory. Separate this bolts for reuse. 5. Remove transmission pan bolts (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4336 6. Remove transmission oil pan (1). 7. Remove oil filter (1) from valve body. It is held in place by two screws. 8. Remove valve body bolts-to-case (1). CAUTION: The overdrive and underdrive accumulators and springs may fall out when removing the valve body. 9. Carefully remove valve body assembly (1) from the transmission. Disassembly DISASSEMBLY NOTE: If the valve body is being reconditioned or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4337 1. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 2. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Remove the pressure control solenoid and line pressure sensor from the valve body 4. Remove the shoulder screw (3) holding the variable line pressure header (4) to the valve body 5. Remove the variable line pressure header from the manual shaft (5). 6. Remove manual shaft seal. 7. Remove manual shaft screw (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4338 8. Remove Transmission Range Sensor (TRS) (1) and manual shaft (2). 9. Remove Solenoid/Pressure Switch Assembly (1) from valve body. 10. Remove valve body stiffener plate (1). 11. Invert valve body assembly and remove transfer plate-to-valve body screws (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4339 12. Remove transfer/separator plate (1) from valve body (2). 13. Remove separator plate-to-transfer plate screws (2). 14. Remove separator plate (1) from transfer plate (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4340 15. Remove the oil screen (1) from the transfer plate. 16. Remove thermal valve (1) from transfer plate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4341 17. Remove valve body check balls (14). Note their location for assembly ease. 18. Remove 2/4 accumulator assembly (15). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4342 19. Remove dual retainer plate (2) from valve body. Use Remover/Installer 6301 (1) to remove plate (2). 20. Remove regulator valve spring retainer (2). 21. Remove remaining retainers (1, 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4343 Valve Body Assembly 22. Remove all valves and springs. 23. Cleanliness through entire disassembly and assembly of the valve body cannot be overemphasized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the valve body are accurately machined, therefore, careful handling of all parts must be exercised to avoid nicks or burrs. Assembly ASSEMBLY NOTE: If the valve body assembly is being reconditioned or replaced, it is necessary to perform the Quick Learn Procedure using the scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4344 1. Install all valves and springs as shown. 2. Install regulator valve spring retainer (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4345 3. Install dual retainer plate (2) using Remover/Installer 6301 (1). 4. Verify that all retainers (1, 2) are installed as shown. Retainers should be flush or below valve body surface. 5. Install 2/4 Accumulator components (15) as shown. Torque 2/4 Accumulator retainer plate to 5 Nm (45 inch lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4346 6. Install check balls into position as shown. If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. 7. Install thermal valve (1) to the transfer plate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4347 8. Install the oil screen (1) to the transfer plate. 9. Install separator plate (1) to transfer plate (2). 10. Install the two separator plate-to-transfer plate screws (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4348 11. Install the transfer plate (1) to the valve body (2). 12. Install the transfer plate-to-valve body screws (1) and torque to 5 Nm (45 inch lbs.). 13. Install the stiffener plate (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4349 14. Install the solenoid/pressure switch assembly (1) and screws to the transfer plate and torque to 5.5 Nm (50 inch lbs.). 15. Install the manual shaft/rooster comb (3) and transmission range sensor (1) to the valve body. 16. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.). 17. Install manual shaft seal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4350 18. Install the variable line pressure header onto the manual shaft (5). 19. Install the shoulder screw (3) to hold the variable line pressure header (4) to the valve body. 20. Install the pressure control solenoid and line pressure sensor into the valve body 21. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 22. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). Installation INSTALLATION 1. Install valve body into position and start bolts (1). Torque valve body to transmission case bolts (1) to 12 Nm (105 inch lbs.) torque. 2. Install transmission oil filter (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4351 NOTE: Before installing the oil pan bolt in the bolt hole (5) located between the torque converter clutch on and U/D clutch pressure tap circuits, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 3. Make sure oil pan (1) and case rail are clean and dry. Install an 1/8" bead of RTV to the transmission oil pan and install to case. Tighten bolts (2) to 20 Nm (14.5 ft. lbs.). 4. Lower vehicle and connect the transmission range sensor (5) connector. 5. Connect solenoid/pressure switch assembly connector. 6. Connect the variable line pressure connector (4), if equipped. 7. Lower vehicle. 8. Fill transmission with ATF+4, Automatic Transmission Fluid. Verify proper fluid level. NOTE: If the valve body has been reconditioned or replaced, it is necessary to perform the Quick Learn Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4352 Valve Body: Service and Repair 45RFE/545RFE Automatic Transmission Removal BODY-VALVE REMOVAL NOTE: The valve body can be removed for service without having to remove the transmission assembly. The valve body can be disassembled for cleaning and inspection of the individual components. 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disconnect wires at the solenoid and pressure switch assembly connector. 4. Position drain pan under transmission oil pan. 5. Remove transmission oil pan. 6. Remove the primary oil filter (1) from valve body. 7. Remove bolts (1) attaching valve body to transmission case. 8. Lower the valve body and work the electrical connector out of transmission case. 9. Separate the valve body from the transmission. Disassembly BODY-VALVE DISASSEMBLY Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4353 1. Remove the bolts (1) holding the solenoid and pressure switch assembly to the valve body. Do not remove the screws on the top of the solenoid and pressure switch assembly. 2. Separate the solenoid and pressure switch assembly from the valve body. 3. Remove the screw holding the detent spring (2) onto the valve body. 4. Remove the detent spring (2) from the valve body. 5. Remove the TRS selector plate (1) from the valve body and the manual valve. 6. Remove the clutch passage seals (3) from the valve body, if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4354 Valve Body Components 7. Remove the screws holding the accumulator cover onto the valve body. 8. Remove the accumulator springs and pistons (1, 69) from the valve body. Note which accumulator piston and spring belong in each location. 9. Place the valve body on the bench with the transfer plate upward. NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to prevent losing the check balls when the transfer plate is removed from the valve body. 10. Remove the screws holding the valve body to the valve body transfer plate. 11. Remove the transfer plate from the valve body. Note the location of all check balls. 12. Remove the check balls from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4355 Valve Body Components 13. Remove the retainers securing the solenoid switch valve (5), manual valve (4), and the low/reverse switch valve (2) from the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly. CLEANING Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4356 Valve Body Components Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only. Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages. INSPECTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4357 Valve Body Components Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat surface. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the accumulator bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4358 Inspect all the fluid seals on the valve body Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance problems. Assembly BODY-VALVE ASSEMBLY 1. Lubricate valves, springs, and the housing valve bores with clean transmission fluid. Valve Body Components 2. Install solenoid switch valve (5), manual valve (4), and the low/reverse switch valve (2) into the valve body 3. Install the retainers to hold each valve into the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4359 4. Install the valve body check balls into their proper locations. 5. Position the transfer plate onto the valve body. 6. Install the screws to hold the transfer plate to the valve body Tighten the screws to 6 Nm (50 inch lbs.). Valve Body Components 7. Install the accumulator pistons (1, 69) and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumulator piston (6) has only one spring. 8. Position the accumulator cover onto the valve body. 9. Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 7 Nm (60 inch lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4360 10. Install the TRS selector plate (1) onto the valve body and the manual valve. 11. Position the detent spring (2) onto the valve body. 12. Install the screw to hold the detent spring (2) onto the valve body. Tighten the screw to 4.5 Nm (40 inch lbs.). 13. Install new clutch passage seals (3) onto the valve body, if necessary. 14. Install the solenoid and pressure switch assembly onto the valve body. 15. Install the bolts (1) to hold the solenoid and pressure switch assembly onto the valve body Tighten the bolts to 6 Nm (50 inch lbs.). Tighten the bolts adjacent to the arrows cast into the bottom of the transfer plate first. Installation BODY-VALVE INSTALLATION 1. Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn. 2. Place TRS selector plate in the PARK position. 3. Place the transmission in the PARK position. 4. Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly. 5. Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4361 6. Seat valve body in case and install one or two bolts to hold valve body in place. 7. Tighten valve body bolts alternately and evenly to 12 Nm (105 inch lbs.) torque. CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 8. Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool. 9. Place replacement filter (1) in position on valve body and into the oil pump. 10. Install screw to hold filter to valve body. Tighten screw to 4.5 Nm (40 inch lbs.) torque. 11. Connect the solenoid and pressure switch assembly connector. 12. Install oil pan. Tighten pan bolts to 12 Nm (105 inch lbs.) torque. 13. Lower vehicle and fill transmission with Mopar ATF +4. 14. Check and adjust gearshift cable, if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair DISC CLUTCH REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool (3) through pressure plate (2) and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. INSTALLATION CAUTION: Before installing a clutch disc on 5.9 L Diesel with Dual Mass Flywheel and self-adjusting pressure plate, the pressure plate must be reset. Failure to reset the pressure will result in damage to the clutch disc. 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI-2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 4366 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: ^ V6 & V8 Engines - 50 Nm (37 ft. lbs.) ^ V10 & Diesel Engines - 30 Nm (22 ft. lbs.) 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair > Page 4367 10. Apply light coat of Mopar high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. 12. Install release lever and bearing in clutch housing. Verify spring clips (2) that retain lever on pivot ball (4) and release bearing (3) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4373 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Page 4374 Clutch Fluid: Specifications Chrysler does not provide a fluid type for the hydraulic clutch system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair LINKAGE REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 4378 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair LINKAGE REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair > Page 4382 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair LINKAGE REMOVAL CAUTION: The hydraulic linkage has a quick disconnect at the slave cylinder. This fitting should never be disconnected or tampered with. Once the hydraulic line is connected to the slave cylinder, it should never be disconnected. 1. Raise and support vehicle. 2. Remove heat shield over hydraulic line. 3. Remove slave cylinder (2) nuts (1) on clutch housing. 4. Remove slave cylinder from clutch housing. 5. Remove plastic clip securing the hydraulic line to the dash panel from the lower dash panel flange. 6. Remove plastic clip securing hydraulic line to the dash panel from the upper dash panel stud. 7. Lower vehicle. 8. Disconnect clutch pedal interlock switch connector (2). 9. Remove clutch master cylinder (1) rod pin (3). 10. Verify that cap on clutch master cylinder reservoir is tight. This will avoid spillage during removal. 11. Remove clutch master cylinder nuts holding cylinder to the dash panel. 12. Remove clutch cylinders, reservoir and connecting lines from vehicle. INSTALLATION 1. Position cylinders and connecting line in vehicle engine compartment. Position clutch hydraulic line against the dash panel and behind all engine hoses and wiring. 2. Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 4386 3. Install clutch master cylinder (1) on dash panel and tighten clutch master cylinder nuts to 28 Nm (21 ft. lbs.). 4. Install clutch master cylinder push rod pin (3). 5. Connect clutch pedal position interlock switch connector (2). 6. Install plastic clip securing hydraulic line to the dash panel into the lower dash panel flange. 7. Install plastic clip securing hydraulic line to the dash panel onto the upper dash panel stud. 8. Raise vehicle. 9. Install slave cylinder (2) and verify cylinder rod is properly seated in release lever. 10. Install and tighten slave cylinder nuts (1) to 23 Nm (17 ft. lbs.). 11. If new clutch linkage is being installed, connect the clutch hydraulic line to the clutch slave cylinder. CAUTION: Once the clutch hydraulic line is connected to the slave cylinder, it should never be disconnected. 12. Install heat shield over hydraulic line. 13. Operate linkage several times to verify proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair BEARING-CLUTCH RELEASE REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Fork, M/T > Component Information > Service and Repair Clutch Release Fork: Service and Repair BEARING-CLUTCH RELEASE REMOVAL 1. Remove transmission and transfer case, if equipped. 2. Remove spring clip (6). 3. Disconnect release bearing (4) from release lever (3) and remove bearing. INSTALLATION 1. Inspect bearing slide surface on transmission front bearing retainer. Replace retainer if slide surface is scored, worn, or cracked. 2. Inspect release lever (2) and pivot stud (1). Verify stud is secure and in good condition and lever is not distorted or worn. Replace fork spring clips if bent or damaged. 3. Lubricate input shaft splines, bearing retainer slide surface, pivot stud (1) and release lever pivot surface with Mopar high temperature bearing grease. 4. Install release fork and release bearing. Verify fork and bearing are properly secured by spring clips and release lever is installed properly Rear side of release lever has one end with a raised area, which goes toward the slave cylinder side of the transmission. 5. Install transmission and transfer case. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Pressure Plate Bolts - V6 & V8 ............................................................................................................ .................................................... 50 Nm (37 ft. lbs.) CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4399 Pressure Plate: Adjustments ADJUSTMENTS PRESSURE PLATE DIAPHRAGM SPRINGS NOTE: Perform the following procedure, when replacing only the clutch disc on 5.9L Diesel with Dual Mass Flywheel and self-adjusting pressure plate. The pressure plate must be reset before installing a new disc. 1. Place pressure plate with disc on a press. 2. Center press ram (2) on the pressure plate diaphragm spring fingers (1). 3. Compress the diaphragm spring fingers (1), until tension is released from the stepped adjusting ring. 4. Place two screwdrivers against two of the three stepped adjusting ring (1) tension spring stops, just ahead of the adjusting ring tension springs on the pressure plate (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4400 5. Rotate stepped adjusting ring (1) on the pressure plate (2) counterclockwise until adjusting ring steps are adjusted out fully. Then hold adjusting ring while releasing the press pressure. 6. Remove the screwdrivers. The pressure plate is know adjusted for a new clutch disc. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4401 Pressure Plate: Service and Repair DISC CLUTCH REMOVAL 1. Support engine with wood block and adjustable jack stand, to prevent strain on engine mounts. 2. Remove transmission and transfer case, if equipped. 3. If pressure plate (3) will be reused, mark (2) the position on flywheel (1) with paint or scriber. Also note location marks on the pressure next to the bolt holes. The mark will be a L or a circle with an X in it. 4. Insert clutch alignment tool (3) through pressure plate (2) and into pilot bushing, to hold disc in place while removing bolts. 5. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 6. Remove bolts completely and remove pressure plate, disc and alignment tool. INSTALLATION CAUTION: Before installing a clutch disc on 5.9 L Diesel with Dual Mass Flywheel and self-adjusting pressure plate, the pressure plate must be reset. Failure to reset the pressure will result in damage to the clutch disc. 1. Check runout and free operation of new clutch disc. 2. Lubricate crankshaft pilot bearing with a NLGI-2 rated grease. 3. Install clutch alignment tool in clutch disc hub with the raised side of hub is facing away from the flywheel. NOTE: Flywheel side is imprinted on the disc face. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4402 4. Install alignment tool (3) in pilot bearing and position disc on the flywheel (1). 5. Position pressure plate over disc (2) and onto the flywheel. 6. Align and hold pressure plate in position and install bolts finger tight. 7. Tighten bolts evenly and a few threads at a time in a diagonal pattern. CAUTION: Bolts must be tightened evenly and to specified torque to avoid warping pressure plate cover. 8. Tighten pressure plate bolts to: ^ V6 & V8 Engines - 50 Nm (37 ft. lbs.) ^ V10 & Diesel Engines - 30 Nm (22 ft. lbs.) 9. Remove release lever (3) and release bearing from clutch housing (1). Apply Mopar high temperature bearing grease to bore (4) of release bearing, release lever (5) contact surfaces and release lever pivot stud (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 4403 10. Apply light coat of Mopar high temperature bearing grease to splines (3) of transmission input shaft (1) and to release bearing slide surface of the transmission front bearing retainer (2). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc. 11. Wipe pilot bearing surface clean. 12. Install release lever and bearing in clutch housing. Verify spring clips (2) that retain lever on pivot ball (4) and release bearing (3) are installed properly. NOTE: If release lever is installed correctly, the lever part number will be toward the bottom of the transmission and right side up. There is also a stamped "I" in the lever which goes to the pivot ball side of the transmission. 13. Install transmission and transfer case if equipped. 14. Check fluid level in clutch master cylinder. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4410 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4415 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair Differential Cover: Service and Repair COVER-DIFFERENTIAL REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove drain plug. 3. Remove cover bolts. 4. Remove cover and drain lubricant. INSTALLATION 1. Apply a 6.35 mm (1/4 inch) bead of Mopar Silicone Rubber Sealant (1) or equivalent to the cover (2). CAUTION: If housing cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will result in a leak. 2. Install cover and identification tag. Tighten cover bolts in a crisscross pattern to 41 Nm (30 ft. lbs.). 3. Fill differential to specifications. 4. Install fill plug. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4424 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4425 Fluid - Differential: Technical Service Bulletins Differential - Fluid Level Inspection Procedure NUMBER: 03-003-06 GROUP: Axle DATE: October 20, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 03-001-04 REV. A, DATED MAY 11, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS. SUBJECT: Axle Fluid Level MODELS: 2004 (AN) Dakota **2004 - 2007** (DR/DH/D1/DC) Ram Truck **2004 - 2007** (HB/HG) Durango / Aspen **2005 - 2007** (ND) Dakota DISCUSSION: The axle fill holes on some Dodge Truck vehicle axles may be located considerably higher than the actual fluid level. Filling the axle until the fluid comes out of the fill hole will over fill the axle, which may cause fluid foaming. When checking fluid level or filling a rear axle with fluid, you must measure the distance from the bottom of the fill hole to the top of the actual fluid level. This can easily be accomplished using a pipe cleaner or piece of wire. Make a 90 degree bend in the wire 2 inches from the end. The wire can then be inserted into the axle fill hole to use as a dipstick. Measure the distance from the bend to the oil level. The fluid levels for the axles are shown in the table below. CORRECT FLUID LEVELS FOR DURANGO / ASPEN: NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4426 The Trac-Lok feature is not available on Durango rear axles. Traction control is provided electronically through the ABS system. Trac-Lok additives or friction modifiers are not required. CORRECT FLUID LEVELS FOR RAM TRUCK 1500: CORRECT FLUID LEVELS FOR RAM TRUCK 2500 -3500: CORRECT FLUID LEVELS FOR DAKOTA: NOTE: The Trac-Lok feature is available on Dakota rear axles. Trac-Lok additives are required on axles equipped with Trac Lok. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Axle Fluid ............................................................................................................................................. ........................................................ +\- 1 oz (0.03L) 9 1/4 .................................................................. ........................................................................................................................................... 72 oz (2.1L) *** 10 1/2 AA ............................................................................................................................. ................................................................................ 85 oz. 2.5L 10 1/2 AA EL .................................... .............................................................................................................................................................. ... 85 oz (2.5L) 11 1/2 AA Open ........................................................................................................... .................................................................................... 142 oz (4.2L) 11 1/2 AA Trac-Rite .................. .............................................................................................................................................................. ......... 135 oz (4.0L) 248RBI (Dana 60) ............................................................................................... ....................................................................................... 46 oz (2.8L)**** *** ............................................................................................................................................. With Trac-Lok add 4 oz (118 ml) of Limited Slip Additive **** ..................................................................... .............................................................................................. Add 5 oz (147 ml) of Limited Slip Additive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 4429 Fluid - Differential: Fluid Type Specifications 9 1/4 ..................................................................................................................................................... ............... Mopar Synthetic Gear Lubricant 75W-140 10 1/2 AA ............................................................................................................................................................. Mopar Synthetic Gear Lubricant 75W-90 10 1/2 AA EL ....................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 11 1/2 AA Open .................................................................................................................................................... Mopar Synthetic Gear Lubricant 75W-90 248RBI (Dana 60) .................................................................................................................................................... Mopar Gear & Axle Lubricant SAE 90 Note: Trac-Lok Differentials require Limited Slip Additive in the lubricant. Trac-Rite/Trac-Rite EL differentials DO NOT require Limited Slip Additive. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI Seals and Gaskets: Service and Repair Rear Axle-248RBI Seal Axle Shaft SEAL AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the end of the axle tube (2) with a seal puller. INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Coat new seal lip with axle lubricant and install seal with Installer 9343 (1) and Handle C4171 (2). 3. Install axle shaft. Seal Pinion SEAL PINION REMOVAL 1. Remove propeller shaft. 2. Remove brake calipers to prevent any drag. 3. Rotate pinion yoke three or four times. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4434 4. Measure and record pinion (2) Torque To Rotate with an inch pound torque wrench (1). 5. Hold yoke with Puller 6719A and remove pinion shaft nut and washer. 6. Remove pinion yoke (1) with Remover C452 (2). 7. Remove pinion seal with seal puller or slide-hammer mounted screw. INSTALLATION 1. Coat lip of pinion seal with gear lubricant. 2. Install new pinion seal with Installer 9348 (2) and Handle C4171 (1). 3. Install yoke on pinion shaft with Installer C3718 and Holder 6719A. 4. Install pinion yoke washer with the concave surface against the yoke end. 5. Install new pinion nut. CAUTION: Never exceed minimum tightening torque when installing the pinion yoke retaining nut at this point. Failure to heed caution may result in damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4435 6. Hold pinion yoke with Holder 6719A (2) and tighten nut with torque wrench (3) to 292 Nm (215 ft. lbs.). Rotate pinion shaft several revolutions to ensure bearing rollers are seated. 7. Measure pinion (2) Torque to Rotate with a inch pound torque wrench (1). Pinion Torque To Rotate is equal to the reading recorded during removal, plus 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage. 8. If rotating torque is low, use Yoke Holder 6719 to hold the pinion yoke and tighten the pinion shaft nut in 6.8 Nm (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. NOTE: The rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. 9. Install brake components. 10. Install propeller shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4436 Seals and Gaskets: Service and Repair Rear Axle-9 1/4 Seal Axle Shaft SEAL AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C4076B and Handle C4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Seal Pinion SEAL PINION REMOVAL 1. Mark universal joint, companion flange and pinion shaft for installation reference. 2. Remove propeller shaft from the companion flange. 3. Remove the brake rotors to prevent any drag. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4437 4. Rotate companion flange (1) three or four times and record pinion rotating torque with an inch pound torque wrench (2). 5. Install two bolts into the companion flange threaded holes, 180° apart. Position Holder 6719A against the companion flange and install and tighten two bolts and washers into the remaining holes. 6. Hold the companion flange with Holder 6719A and remove pinion nut and washer. 7. Remove companion flange with Puller C452 (2). 8. Remove pinion seal with seal puller or slide-hammer mounted screw. INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4438 2. Install new pinion seal (3) with Handle C4735 and Installer C4076B (1). 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C3718 and Holder 6719A (2). 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. CAUTION: Never exceed the minimum tightening torque 285 Nm (210 ft. lbs.) when installing the companion flange retaining nut at this point. Failure to follow these instructions will damage the collapsible spacer. 8. Hold companion flange with Holder 6719A (2) and tighten the pinion nut with a torque set to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated. 9. Measure pinion Torque To Rotate with an inch pound torque wrench (2). Pinion Torque To Rotate should be equal to the reading recorded during removal plus an additional 0.56 Nm (5 inch lbs.). CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque and never exceed specified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. 10. If torque to rotate is low, use Holder 6719 to hold the companion flange (1) and tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion Torque To Rotate is achieved. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4439 NOTE: The bearing rotating torque should be constant during a complete revolution of the pinion. If the rotating torque varies, this indicates a binding condition. NOTE: The seal replacement is unacceptable if the final pinion nut torque is less than 285 Nm (210 ft. lbs.). 11. Install propeller shaft with the installation reference marks aligned. 12. Install brake rotors. 13. Check the differential lubricant level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4440 Seals and Gaskets: Service and Repair Rear Axle-10 1/2 AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Measure and record the amount of torque necessary to rotate the pinion gear (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Wrench 8979 (2) and remove pinion flange nut and washer. 6. Remove pinion flange (1) with Puller 8992 (2). 7. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4441 1. Install new pinion seal with Installer 8896 (2) and Handle C4171 (1). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. 8. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 9. Rotate pinion several times then verify pinion Torque To Rotate again. 10. Install axle shafts. 11. Install propeller shaft with reference marks aligned. 12. Check and fill differential if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4442 Seals and Gaskets: Service and Repair Rear Axle-11 1/2 AA SEAL PINION REMOVAL 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 8. Remove pinion shaft seal with a seal puller or slide hammer mounted screw. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Rear Axle-248RBI > Page 4443 1. Install new pinion seal with Handle C4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion Torque To Rotate again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI Axle Bearing: Service and Repair Rear Axle-248RBI BEARING AXLE REMOVAL 1. Remove axle shaft. 2. Remove axle seal with pry bar. 3. Position bearing (2) Receiver 9345 (1) on axle tube. 4. Insert bearing Remover 6310 with Foot 63109 (3) through receiver (2) and bearing (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4449 5. Tighten Remove 6310 nut (1) to pull bearing into the receiver (3). INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Install axle shaft bearing with Installer 9344 (1) and Handle C4171 (2). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat new axle seal lip with axle lubricant and install with Installer 9343 and Handle C4171. 4. Install axle shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4450 Axle Bearing: Service and Repair Rear Axle-9 1/4 BEARING AXLE REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal from axle tube with a small pry bar. NOTE: The seal and bearing can be removed at the same time with the bearing removal tool. 3. Remove axle shaft bearing with Bearing Remover 6310 (2) (3) (4) (5) and Foot 63109 (7). INSTALLATION 1. Wipe axle tube bore clean and remove any old sealer or burrs from the tube. 2. Install axle shaft bearing with Installer C4198 and Handle C4171. Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat lip of the new axle seal with axle lubricant and install with Installer C4076B and Handle C4735. 4. Install the axle shaft (1). 5. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4451 Axle Bearing: Service and Repair Rear Axle-10 1/2 AA BEARINGS AXLE HUB REMOVAL 1. Remove axle shaft flange bolts and remove axle shaft. 2. Remove retainer ring (1) from axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) from axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4452 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C4171. 2. Install inner hub bearing cup with Installer 8962 and Handle C4171. 3. Pack bearings with the appropriate grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. End play should be 0.025 - 0.25 mm (0.001 0.010 inch). 8. Install retainer ring (1) with ring end in the key slot (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4453 9. Install new axle shaft gasket and install axle shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4454 Axle Bearing: Service and Repair Rear Axle-11 1/2 AA BEARINGS AXLE HUB REMOVAL 1. Remove axle shaft flange bolts and remove shaft. 2. Remove retainer ring (1) from the axle shaft tube. 3. Remove hub bearing nut (1) locking key (2) form axle tube (3). 4. Remove hub bearing nut with Socket 8954. 5. Remove hub and bearings from the axle. 6. Pry out hub bearing seal from the back of the hub. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4455 NOTE: The inner part of the seal (3) may stay on the axle tube (2). This part must also be removed with a pry bar (1). 7. Remove rear bearing. 8. Remove hub bearing cups with a hammer and drift. INSTALLATION 1. Install outer hub bearing cup with Installer 8961 and Handle C4171. 2. Install inner hub bearing cup with Installer 8153 and Handle C4171. 3. Pack bearings with the appropriate wheel bearing grease. 4. Install rear bearing and install new grease seal with Installer 8963 and Handle C4171. 5. Slide hub on the axle tube and install front bearing into the hub. 6. Install hub bearing nut with Socket 8954 (1) and tighten with torque wrench (2) to 30 Nm (22 ft. lbs.) while rotating the hub. 7. Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: End play should be 0.025 - 0.25 mm (0.01 - 0.001 inch) 8. Install retainer ring (1) with ring end in the key slot (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Rear Axle-248RBI > Page 4456 9. Install new axle shaft gasket and install the axle shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures Axle Shaft: Procedures Rear Axle-10 1/2 AA SHAFT-AXLE REMOVAL 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. INSTALLATION NOTE: Axle flange bolts must be replaced or cleaned existing bolts apply Mopar Lock 'N Seal or Loctite 242 on the threads. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm (95 ft. lbs.). Rear Axle-11 1/2 AA SHAFT AXLE REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 4462 1. Remove axle shaft flange (1) bolts (2). 2. Slide axle shaft out of the axle tube. 3. Remove axle shaft gasket. INSTALLATION NOTE: Axle flange bolts must be replaced or use Mopar Lock 'N Seal or Loctite 242 on cleaned existing bolts. 1. Clean axle flange and hub. 2. Install new axle shaft gasket. 3. Slide axle shaft into the axle tube. 4. Install axle shaft flange (1) bolts (2) and tighten to 129 Nm ( 95 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 4463 Axle Shaft: Removal and Replacement Rear Axle - 10 1/2 AA REAR AXLE-10 1/2 AA REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. 4. Remove axle vent hose. 5. Mark propeller shaft and companion flange for installation alignment reference. 6. Remove propeller shaft. 7. Remove shock absorbers (3) from axle (2). 8. Remove U-bolts (5) from axle. 9. Remove axle from the vehicle. INSTALLATION 1. Raise axle with lift and align to the leaf spring centering bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 4464 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install axle vent hose. 6. Install propeller shaft with reference marks aligned and tighten to specification. 7. Fill differential to specifications. Rear Axle - 11 1/2 AA REAR AXLE-11 1/2 AA REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Position a lift under axle and secure lift to the axle. 3. Remove all brake components. 4. Mark propeller shaft and companion flange for installation alignment reference. 5. Remove propeller shaft. 6. Remove axle vent hose. 7. Remove shock absorbers (3) from axle (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Procedures > Page 4465 8. Remove U-bolts (4) from axle. 9. Remove axle from the vehicle. INSTALLATION 1. Raise axle with lift and align to the leaf spring (1) centering bolts. 2. Install axle U-bolts (5) and tighten to 149 Nm (110 ft. lbs.). 3. Install shock absorbers to axle and tighten to specification. 4. Install all brake components. 5. Install propeller shaft with reference marks aligned and tighten to specification. 6. Install axle vent hose. 7. Fill differential to specifications. 8. Remove lift from axle and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle-10 1/2 AA Seals and Gaskets: Service and Repair Rear Axle-10 1/2 AA SEAL-PINION REMOVAL 1. Remove axle shafts. 2. Mark propeller shaft and pinion flange for installation reference and remove shaft. 3. Rotate pinion gear three or four times. 4. Measure and record the amount of torque necessary to rotate the pinion gear (1) with an inch pound torque wrench (2). 5. Hold pinion flange (1) with Wrench 8979 (2) and remove pinion flange nut and washer. 6. Remove pinion flange (1) with Puller 8992 (2). 7. Remove pinion shaft seal with a pry tool or slide hammer mounted screw. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle-10 1/2 AA > Page 4470 1. Install new pinion seal with Installer 8896 (2) and Handle C4171 (1). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. 8. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 9. Rotate pinion several times then verify pinion Torque To Rotate again. 10. Install axle shafts. 11. Install propeller shaft with reference marks aligned. 12. Check and fill differential if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle-10 1/2 AA > Page 4471 Seals and Gaskets: Service and Repair Rear Axle-11 1/2 AA SEAL PINION REMOVAL 1. Remove axle shafts. 2. Mark the propeller shaft and pinion flange for installation reference. 3. Remove propeller shaft. 4. Rotate pinion gear (1) three or four times. 5. Measure and record the amount of torque necessary to rotate the pinion gear with an inch pound torque wrench (2). 6. Hold pinion flange (1) with Flange Wrench 8979 (2) and remove pinion flange nut. 7. Remove pinion flange (1) with Pinion Flange Puller 8992 (2). 8. Remove pinion shaft seal with a seal puller or slide hammer mounted screw. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle-10 1/2 AA > Page 4472 1. Install new pinion seal with Handle C4171 (1) and Installer 8896 (2). 2. Apply a light coat of teflon sealant to the pinion flange splines. 3. Lightly tap the pinion flange onto the pinion until a few threads are showing. 4. Install flange washer and new pinion nut. 5. Hold pinion flange (2) with Flange Wrench 8979 (1) and tighten pinion nut until pinion end play is taken up. 6. Rotate pinion several times to seat bearings. 7. Measure pinion (1) Torque To Rotate with an inch pound torque wrench (2) and compare it to recorded measurement. Tighten pinion nut in small increments, until pinion Torque To Rotate is 0.40 - 0.57 Nm (3 - 5 inch lbs.) greater than recorded measurement. 8. Rotate pinion several times then verify pinion Torque To Rotate again. 9. Install axle shafts. 10. Install propeller shaft with reference marks aligned. 11. Check differential fluid level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle-10 1/2 AA > Page 4473 Seals and Gaskets: Service and Repair Rear Axle-248RBI SEAL AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the end of the axle tube (2) with a seal puller. INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Coat new seal lip with axle lubricant and install seal with Installer 9343 (1) and Handle C4171 (2). 3. Install axle shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair > Rear Axle-10 1/2 AA > Page 4474 Seals and Gaskets: Service and Repair Rear Axle-9 1/4 SEAL AXLE SHAFT REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from the axle tube with a seal puller. INSTALLATION 1. Wipe the axle tube bore clean. Remove any old sealer or burrs from the tube. 2. Coat the lip of the new seal with axle lubricant and install a seal with Installer C4076B and Handle C4735. NOTE: When tool contacts the axle tube, the seal is installed to the correct depth. 3. Install the axle shaft (1). 4. Install differential cover and fill with gear lubricant to the bottom of the fill plug hole. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4487 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4488 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4489 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4490 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4491 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4492 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4493 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4503 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4504 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4505 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4506 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4507 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4508 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4509 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Page 4510 Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Removal Wheel Bearing: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Removal > Page 4513 Wheel Bearing: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4526 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4527 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4528 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4529 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4530 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4531 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4532 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4542 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4543 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4544 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4545 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4546 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4547 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4548 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Removal Wheel Hub: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Service and Repair > Removal > Page 4551 Wheel Hub: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4560 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4561 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4562 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4563 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4564 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4565 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4566 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4572 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4573 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4574 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4575 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4576 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4577 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 4578 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD Center Support: Service and Repair Bearing-Center LD BEARING-CENTER LD REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference marks on the shaft (1) and slip yoke (2). 3. Remove slip joint boot (1) clamp (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD > Page 4584 4. Slide boot (1) off boot collar (2) and separate the two shafts. 5. Position Bearing Splitter Tool 1130 (2) between slinger and center bearing (1). 6. Install Bridge 938 (3) on the splitter (2) and remove center bearing (1). INSTALLATION 1. Install new slinger on shaft if removed and drive into position with appropriate installer tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD > Page 4585 2. Install new center bearing (1) and boot collar (2) on shaft. 3. Install bearing (1) and boot collar (2) on shaft with Installer 6052 (3). 4. Clean shaft splines and apply a coat of multi-purpose grease. 5. Align master splines and slide front and rear half shafts together. 6. Position slip yoke boot (1) on boot collar and install clamp (2). 7. Install propeller shaft in vehicle. ADJUSTMENTS BEARING CENTER Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 3.0 mm (0.125 inch) increments. Use shim stock or fabricated plates. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD > Page 4586 Center Support: Service and Repair Bearing-Center HD BEARING-CENTER HD REMOVAL 1. Remove rear propeller shaft. 2. Make installation reference marks on rear shaft (1) and front shaft (2). 3. Remove slip joint boot (1) clamp (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD > Page 4587 4. Slide boot (1) off boot collar (2) and separate the two shafts. 5. Position Bearing Splitter Tool 1130 (1) between propeller shaft and center bearing (2). 6. Install Bridge 938 (3) on the splitter (1) and remove center bearing. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD > Page 4588 1. Slide center bearing (1) and boot collar (2) on shaft. 2. Install boot collar (2) and center bearing (1) with Installer 6448A. 3. Clean shaft splines and apply a coat of multi-purpose grease. 4. Align master splines and slide front and rear half-shafts together. 5. Slide slip yoke boot (1) on boot collar (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Bearing-Center LD > Page 4589 6. Install slip yoke boot (1) clamp (2). 7. Install propeller shaft in vehicle. ADJUSTMENTS BEARING CENTER Launch shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usually peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft. To decrease shudder, lower the center bearing in 3.0 mm (0.125 inch) increments. Use shim stock or fabricated plates. Do not use washers. Replace the original bolts with the appropriate increased length bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications TORQUE SPECIFICATIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4593 Drive/Propeller Shaft: Testing and Inspection DIAGNOSIS AND TESTING PROPELLER SHAFT PROPELLER SHAFT VIBRATION Out of round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also be caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. DRIVELINE VIBRATION PROPELLER SHAFT BALANCE If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180 degrees relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4594 6. Remove wheels and install lug nuts to retain brake rotors. 7. Mark and number the shaft six inches from the pin ion yoke end at four positions 90 degrees apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 4595 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle Drive/Propeller Shaft: Service and Repair Propeller Shaft Angle PROPELLER SHAFT ANGLE ONE PIECE PROPELLER SHAFT This procedure applies to front and rear propeller shafts. NOTE: To obtain output angle (A) on the front propeller shaft equipped with a C/V joint, place inclinometer on machined surface of the C/V joint. 1. Raise vehicle and support the axles as level as possible, allowing the wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base sits flat. 3. Rotate shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always take measurements from front to rear and on the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission yoke Output Angle (A). 5. Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement can also be taken at the rear end of the shaft. This measurement will give you the Propeller Shaft Angle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4598 6. Rotate propeller shaft 90 degrees and place inclinometer on companion flange yoke bearing parallel to the shaft. Center bubble in sight glass and record measurement. This measurement will give you the pinion Companion Flange Input Angle (B). 7. Subtract smaller figure from larger (C minus A) to obtain Transmission/Transfer Case Output Operating Angle. 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. RULES ^ Good cancellation of U-joint operating angles should be within 1 degree. ^ Operating angles should be less than 3 degrees. ^ Operating angles less than 10 degrees for double cardan U-joint. ^ At least 1/2 of one degree continuous operating propeller shaft angle. TWO PIECE PROPELLER SHAFT Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4599 Two piece propeller shaft angles measurement is the same as a one-piece propeller shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4600 Drive/Propeller Shaft: Service and Repair Shaft-Propeller Rear LD SHAFT-PROPELLER REAR LD REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark propeller shaft (1) pinion flange (2) and propeller shaft flange (4) with installation reference marks (3). 3. If equipped with manual transmission, mark manual transmission flange (1) and propeller shaft (2) flange for installation reference. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4601 4. If equipped with a center bearing (1) mark an outline of the center bearing (1) on the center bearing bracket for installation reference. Then support propeller shaft and remove mounting bolts (2). 5. Remove pinion flange (1) bolts from propeller shaft (2). 6. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4602 7. If equipped with manual transmission remove flange (1) bolts (2). 8. Remove propeller shaft from vehicle. CAUTION: Failure to follow these instructions may result in a driveline vibration. INSTALLATION 1. Slide slip yoke (1) onto automatic transmission/ transfer case output shaft (2) with reference marks aligned. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4603 2. If equipped with manual transmission, align transmission flange (1) and propeller shaft reference marks. Install new flange bolts (2) and tighten to 115 Nm (85 ft. lbs.). 3. If two piece propeller shaft, align center bearing (1) with reference marks on center bearing bracket and tighten bolts (2) to 54 Nm (40 ft. lbs.). 4. Align reference marks on propeller shaft and pinion flange. Install new companion flange (1) bolts and tighten to 115 Nm (85 ft. lbs.) CAUTION: Failure to follow these instruction may result in a driveline vibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4604 Drive/Propeller Shaft: Service and Repair Shaft-Propeller Rear HD SHAFT-PROPELLER REAR HD REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark propeller shaft (1) pinion flange (2) and propeller shaft flange (4) with installation reference marks (3). 3. If equipped with manual transmission, mark manual transmission flange (1) and propeller shaft flange (2) for installation reference. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4605 4. If equipped with a center bearing (1) mark an outline of the center bearing on the center bearing bracket for installation reference. Then support propeller shaft and remove center bearing bolts (2). 5. Remove pinion flange (1) bolts from propeller shaft (2). 6. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4606 7. If equipped with manual transmission remove flange (1) bolts (2). 8. Remove propeller shaft from vehicle. CAUTION: Failure to follow these instructions may result in a driveline vibration. INSTALLATION 1. Slide slip yoke (1) onto automatic transmission/ transfer case output shaft (2) with reference marks aligned. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Propeller Shaft Angle > Page 4607 2. If equipped with manual transmission, align transmission flange (1) and propeller shaft reference marks. Install new flange bolts (2) and tighten to 115 Nm (85 ft. lbs.). 3. If two piece propeller shaft, align center bearing (1) with reference marks on center bearing bracket and tighten bolts (2) to 54 Nm (40 ft. lbs.). 4. Align reference marks on propeller shaft and pinion flange. Install new companion flange (1) bolts and tighten to 115 Nm (85 ft. lbs.). CAUTION: Failure to follow these instruction may result in a driveline vibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 4608 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan Universal Joint: Service and Repair Universal Joints-Single Cardan With Injected Ring UNIVERSAL JOINTS-SINGLE CARDAN DISASSEMBLY-WITH INJECTED RING 1. Place shaft yoke in vise. 2. Position U-joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-joint bearing caps (1) out of shaft yoke (2). 4. Remove lower bearing cap from shaft yoke. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4613 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-joint out of shaft yoke (2). 8. Position U-joint press (2) with receiver (1) on flange. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4614 9. Press U-joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-joint press (2) with receiver (1) on flange. 12. Press remaining U-joint bearing cap out of flange. 13. Remove U-joint from flange. ASSEMBLY NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4615 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). 4. Install snap ring (2) on bearing (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4616 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). 8. Install flange (1) with U-joint in yoke (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4617 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4618 14. Install snap ring (2) on bearing cap (1). With Snap Rings UNIVERSAL JOINTS-SINGLE CARDAN DISASSEMBLY-WITH SNAP RINGS 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. 3. Position yoke with the grease fitting if equipped, pointing up. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4619 4. Position a socket (2) with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If bearing cap will not pull out of the yoke after pressing, tap yoke ear near bearing cap to dislodge the cap. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. ASSEMBLY 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke (2) with lube fitting pointing up, if equipped. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4620 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat Step 3 and Step 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. 7. Install propeller shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4621 Universal Joint: Service and Repair Universal Joints-Double Cardan UNIVERSAL JOINTS-DOUBLE CARDAN DISASSEMBLY 1. Remove propeller shaft. 2. Mark propeller shaft, link yoke and flange yoke for assembly reference. 3. Tap outside of the bearing cap assembly with drift to loosen snap rings. 4. Remove all bearing cap snap rings. 5. Remove grease fittings if equipped. 6. Position a socket on the press with an inside diameter large enough to receive the bearing cap under the link yoke. 7. Place another socket with an outside diameter smaller than the bearing cap on the upper bearing cap. 8. Press one bearing cap from outboard side of the link yoke, enough to grasp the cap with vise jaws. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4622 9. Grasp protruding bearing cap with vise jaws and tap link yoke with a mallet to remove bearing cap. 10. Flip assembly and repeat Step 6, Step 7, Step 8 and Step 9 to remove the opposite bearing cap. 11. Remove cross centering kit assembly and spring. 12. Press remaining bearing caps out the other end of the link yoke. ASSEMBLY CAUTION: All alignment marks on the link yoke and propeller shaft yoke must be aligned during assembled. 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Fit cross into the propeller shaft yoke. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4623 3. Place bearing cap over the trunnion and align cap with the yoke bore. Keep needle bearings upright in the bearing cap. 4. Press bearing cap into yoke bore enough to clear snap ring groove and install snap-ring. 5. Flip propeller shaft yoke and install other bearing cap onto the opposite trunnion and install a snap ring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4624 6. Fit link yoke onto remaining trunnions and press both bearing caps into place and install snap rings. 7. Install centering kit assembly inside the link yoke. NOTE: Verify spring is properly positioned. 8. Place two bearing caps on opposite trunnions of the remaining cross. Fit open trunnions into the link yoke bores and bearing caps into the centering kit. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Universal Joints-Single Cardan > Page 4625 9. Press remaining two bearing caps into place and install snap rings. 10. Tap snap rings to seat them into the grooves. 11. Flexing the joint beyond center, the joint should snap overcenter in both directions if correctly assembled. 12. Install propeller shaft. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate to Crankshaft-Bolts .............................................................................................................. ...................................................... 95 Nm (70 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 4629 Flex Plate: Service and Repair FLEX PLATE REMOVAL 1. Remove the transmission. 2. Remove the bolts and flexplate (1). INSTALLATION 1. Position the flexplate or flywheel onto the crank shaft and install the bolts hand tight. 2. For automatic transmissions: Tighten the flex plate retaining bolts to 95 Nm (70 ft. lbs.). 3. Install the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel to Crankshaft-Bolts ............................................................................................................... ..................................................... 75 Nm (55 ft. lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 4633 Flywheel: Description and Operation FLYWHEEL DESCRIPTION STANDARD FLYWHEEL The Standard Flywheel (3) is a heavy plate bolted to the rear of the crankshaft (1). The flywheel incorporates the ring gear (2) around the outer circumference to mesh with the starter to permit engine cranking. The rear face of the flywheel serves as the driving member to the clutch disc. DUAL MASS FLYWHEEL The Dual Mass Flywheel is used on the 5.9L Diesel engine with G56 transmission. The flywheel incorporates the ring gear (1) around the outer circumference to mesh with the starter to permit engine cranking. The primary flywheel side is bolted to the crankshaft. The secondary flywheel side serves as the driving member to the clutch disc. Internal springs (2) are used to dampen energy. The Dual Mass Flywheel is serviced as an assembly only and should never be taken apart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 4634 Flywheel: Testing and Inspection FLYWHEEL Check flywheel (3) runout whenever misalignment is suspected. Flywheel runout should not exceed 0.08 mm (0.003 inch). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the indicator on a stud installed in place of one of the flywheel bolts. Common causes of runout are: ^ heat warpage ^ improper machining ^ incorrect bolt tightening ^ improper seating on crankshaft flange shoulder ^ foreign material on crankshaft flange Flywheel machining is not recommended. The flywheel clutch surface is machined to a unique contour and machining will negate this feature. Minor flywheel scoring can be cleaned up by hand with 180 grit emery or with surface grinding equipment. Remove only enough material to reduce scoring ( approximately 0.001 - 0.003 inch). Heavy stock removal is not recommended. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 inch). Excessive stock removal can result in flywheel cracking or warpage after installation; it can also weaken the flywheel and interfere with proper clutch release. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar Lock And Seal or equivalent. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout. On a Dual Mass Flywheel (1) inspect all springs (2) for damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications > Page 4635 Flywheel: Service and Repair FLYWHEEL REMOVAL 1. Remove transmission. 2. Loosen pressure plate bolts evenly, a few threads at a time and in a diagonal pattern to prevent warping the plate. 3. Remove bolts completely and remove pressure plate and disc. 4. Remove flywheel bolts and remove flywheel. NOTE: Vehicles with Dual Mass Flywheel use an adapter plate between the flywheel and crank. This plate does not need to be removed. INSTALLATION 1. Install flywheel on the crankshaft. 2. Install flywheel bolts and tighten evenly in sequence to 95 Nm (70 ft. lbs.). Vehicles with Dual Mass Flywheel, tighten bolts to 55 Nm (40 ft. lbs.) . 3. Install clutch. 4. Install transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. The overdrive off indicator gives an indication to the vehicle operator when the overdrive off feature has been selected using the tow/haul switch, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the overdrive off indicator for the following reasons: - Overdrive Off Lamp-On Message - Each time the cluster receives an overdrive off lamp-on message from the PCM indicating that the overdrive off feature has been selected, the overdrive off indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive off lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive off lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the overdrive off indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 4642 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text "TOW/HAUL" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the tow/haul feature has been selected using the tow/haul switch, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the transmission temperature sensor, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type and model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Controller Area Network (CAN) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the Transmission Range Sensor (TRS), then sends the proper gear selector indicator position messages to the instrument cluster. On vehicles without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, refer to testing. For further diagnosis of the TRS on vehicles without a TCM, refer to Transmission and Drivetrain/Automatic Transmission/ Transaxle. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Actuators and Solenoids M/T > Shift Solenoid, M/T > Component Information > Description and Operation Shift Solenoid: Description and Operation SOLENOID REVERSE LOCKOUT DESCRIPTION The reverse lockout solenoid prevents shifting into reverse when the vehicle speed is greater than 5 mph. Solenoid is threaded into the left side of the transmission. OPERATION When vehicle speed is less than 5 mph, the PCM provides a ground for the solenoid (energized) and allows shifting. When vehicle speed is greater than 5 mph, the solenoid is deactivated and prevents the transmission from being shifted into reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4659 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4664 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications 5.7L G56 .............................................................................................................................................. ............................................................. 10 pts (4.7L) GETRAG 238 ...................................................................................................................................... ............................................................. 4.6 pts (2.2L) TREMEC T-56 ..................................................................................................................................... .......................................................... 4.8 pts (2.27L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 4667 Fluid - M/T: Fluid Type Specifications Manual Transmission Fluid Type ......................................................................................................... .......................................................... Mopar ATF+4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair Input Shaft: Service and Repair SHAFT INPUT REMOVAL NOTE: If input shaft is damaged behind the seal, the transmission must be disassembled and inspected. 1. Remove transmission from the vehicle. 2. Measure output shaft end play and record number. 3. Remove clutch slave cylinder from transmission adapter plate. 4. Remove front adapter plate bolts (1). 5. Pry front cover adapter loose. 6. Hold input shaft while removing adapter (2). 7. Remove sealant from transmission adapter. 8. Clean and inspect all sealing surfaces for wear or damage. 9. Lift counter shaft slightly and remove input shaft (2) from transmission (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair > Page 4671 10. Remove input shaft bearing (1) with Splitter P334 (2) and a press. INSTALLATION 1. Install new seal from the fluid side with Installer 9366. 2. Install input shaft bearing (2) on shaft with Installer 6052 and Installer MB991317 (2). 3. Install new bearing cup in front adapter with original shim behind cup. 4. Clean sealing surfaces of the transmission case and adapter plate. 5. Install new input shaft and adapter plate (without any Mopar Gasket Maker). 6. Check output shaft end play. It should be the same as measured during the disassemble procedure. If end play is greater than original reading, install a thicker shim. If end play is less than original reading, install a thinner shim. 7. After the correct shim has been installed, remove the adapter plate and apply Mopar Gasket Maker to the sealing surfaces. 8. Install adapter and tighten adapter bolts to 34 Nm (25 ft. lbs.). 9. Install transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Seals and Gaskets, M/T > System Information > Service and Repair Seals and Gaskets: Service and Repair SEAL-EXTENSION HOUSING REMOVAL NOTE: If extension housing slip yoke bushing is worn the housing must be replaced, 1. Remove propeller shaft. 2. Remove seal with a seal pick (1). 3. Clean and inspect extension housing where the seal was located. INSTALLATION 1. Install seal into extension housing (3) with Installer 9372 (1) and Handle C4171(2). 2. Install propeller shaft. 3. Check transmission fluid level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Solenoid, M/T > Component Information > Description and Operation Shift Solenoid: Description and Operation SOLENOID REVERSE LOCKOUT DESCRIPTION The reverse lockout solenoid prevents shifting into reverse when the vehicle speed is greater than 5 mph. Solenoid is threaded into the left side of the transmission. OPERATION When vehicle speed is less than 5 mph, the PCM provides a ground for the solenoid (energized) and allows shifting. When vehicle speed is greater than 5 mph, the solenoid is deactivated and prevents the transmission from being shifted into reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition ON voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4683 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift and shift points, depending on the present operating conditions and driver demand. This is possible through control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the Quick Learn Procedure must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4684 By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the Monitors display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE 545RFE SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4685 Part 1 Part 2 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4690 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4691 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4692 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4693 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4694 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4695 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4696 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4697 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4698 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4699 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4700 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4701 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4702 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4703 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4704 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4705 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4706 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4707 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4708 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4709 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description Transmission Control System Relay: Description and Operation Description DESCRIPTION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description > Page 4712 Transmission Control System Relay: Description and Operation Operation OPERATION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4718 Sensor - Line Pressure (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Description and Operation 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4721 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE DESCRIPTION The line pressure sensor (2) is mounted on the top of the valve body, next to the pressure control solenoid 0). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4722 Fluid Pressure Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Line Pressure SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4723 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4726 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4727 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4728 Fluid Pressure Sensor/Switch: Service and Repair 45RFE/545RFE Automatic Transmission Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4729 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Sensor-Line Pressure SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pres sure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4730 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4734 Switch - Tow/Haul Overdrive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Switch: Description and Operation 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4737 Overdrive Switch: Description and Operation 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4740 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4741 Overdrive Switch: Service and Repair 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4742 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4746 Switch - Clutch Interlock (M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4751 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4752 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4753 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4756 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4757 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4758 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4762 Transmission Speed Sensor: Diagrams Sensor - Input Speed (RFE/RLE) Sensor - Output Speed (RFE/RLE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Speed Sensor: Description and Operation 42RLE Automatic Transmission Sensor Output Speed SENSOR OUTPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor Input Speed SENSOR INPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4765 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4766 Transmission Speed Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Speed Sensor: Service and Repair 42RLE Automatic Transmission Sensor Input Speed SENSOR INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor (1) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor Output Speed SENSOR OUTPUT SPEED REMOVAL 1. Raise vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4769 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor(2). NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor (2) from the transmission case. INSTALLATION 1. Install the output speed sensor (2) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4770 Transmission Speed Sensor: Service and Repair 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the trans mission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor-Output Speed SENSOR-OUTPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4771 3. Remove the wiring connector from the output speed sensor(1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Temperature Sensor/Switch: Description and Operation 42RLE Automatic Transmission Sensor Transmission Range SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Sensor Transmission Temperature SENSOR TRANSMISSION TEMPERATURE DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4776 The transmission temperature sensor (2) is located in the transmission range sensor (1) and communicates transmission sump temperature to the TCM. OPERATION The transmission range sensor (TRS) has an integrated thermistor that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The TCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4777 Transmission Temperature Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Temperature SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4778 Transmission Temperature Sensor/Switch: Service and Repair SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4779 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4786 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4791 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4799 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4800 Overdrive Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4801 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4804 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4805 Overdrive Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Overdrive Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4806 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams Assembly - Transmission Solenoid/TRS (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Pressure Regulating Solenoid: Description and Operation 42RLE Automatic Transmission Solenoid Pressure Control SOLENOID - PRESSURE CONTROL DESCRIPTION The pressure control solenoid (1) is mounted on the top of the valve body, next to the line pressure sensor (2). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The pressure control solenoid (PCS) is a variable force (VFS) style solenoid. A VFS solenoid is an electrohydraulic actuator, combining a solenoid and a regulating valve. The transmission control module varies the current for the PCS, which varies the pressure in the line pressure hydraulic circuit. When the current (duty cycle) of the PCS is low, the pressure in the circuit is higher. At 0 current (0% duty cycle), the pressure is at the maximum value. Conversely, when the current is maximized (100% duty cycle), the pressure in the circuit is at the lowest possible value. Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4812 The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4813 gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4814 Pressure Regulating Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4815 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Pressure Regulating Solenoid: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4818 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Solenoid Pressure Control SOLENOID PRESSURE CONTROL REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4819 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4820 Pressure Regulating Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4821 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4825 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4826 Solenoid - Brake Transmission Shift Interlock Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Shift Solenoid: Description and Operation 42RLE Automatic Transmission ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4832 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4833 Shift Solenoid: Description and Operation 45RFE/545RFE Automatic Transmission Valve-Solenoid Switch VALVE-SOLENOID SWITCH DESCRIPTION The Solenoid Switch Valve (SSV) is located in the valve body and controls the direction of the transmission fluid when the L/R-TCC solenoid is energized. OPERATION The Solenoid Switch Valve controls line pressure from the L/R-TCC solenoid. In 1st gear, the SSV will be in the downshifted position, thus directing fluid to the L/R clutch circuit. In 2nd, 3rd, 4th, and 5th (if applicable) gears, the solenoid switch valve will be in the upshifted position and directs the fluid into the torque converter clutch (TCC) circuit. When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the movement is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4834 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Shift Solenoid: Service and Repair 42RLE Automatic Transmission ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4837 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4838 Shift Solenoid: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4839 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - M/T > Shift Solenoid, M/T > Component Information > Description and Operation Shift Solenoid: Description and Operation SOLENOID REVERSE LOCKOUT DESCRIPTION The reverse lockout solenoid prevents shifting into reverse when the vehicle speed is greater than 5 mph. Solenoid is threaded into the left side of the transmission. OPERATION When vehicle speed is less than 5 mph, the PCM provides a ground for the solenoid (energized) and allows shifting. When vehicle speed is greater than 5 mph, the solenoid is deactivated and prevents the transmission from being shifted into reverse. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. The overdrive off indicator gives an indication to the vehicle operator when the overdrive off feature has been selected using the tow/haul switch, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the overdrive off indicator for the following reasons: - Overdrive Off Lamp-On Message - Each time the cluster receives an overdrive off lamp-on message from the PCM indicating that the overdrive off feature has been selected, the overdrive off indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive off lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive off lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the overdrive off indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 4850 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text "TOW/HAUL" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the tow/haul feature has been selected using the tow/haul switch, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the transmission temperature sensor, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type and model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Controller Area Network (CAN) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the Transmission Range Sensor (TRS), then sends the proper gear selector indicator position messages to the instrument cluster. On vehicles without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, refer to testing. For further diagnosis of the TRS on vehicles without a TCM, refer to Transmission and Drivetrain/Automatic Transmission/ Transaxle. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation Control Module: Description and Operation The Transmission Control Module (TCM) (2) may be sub-module within the Powertrain Control Module (PCM) (3). Or, for vehicles with a diesel engine, the Engine Control Module (ECM) (1). The PCM, and TCM when equipped, is located at the right rear of the engine compartment, near the right inner fender. The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition ON voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4862 - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift and shift points, depending on the present operating conditions and driver demand. This is possible through control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the Quick Learn Procedure must be performed. BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4863 By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the Monitors display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE 545RFE SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Page 4864 Part 1 Part 2 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions Transmission Control System Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4869 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4883 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4884 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4885 Transmission Control System Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4886 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4887 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 4888 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description Transmission Control System Relay: Description and Operation Description DESCRIPTION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > Description > Page 4891 Transmission Control System Relay: Description and Operation Operation OPERATION 545RFE NOTE: Due to different power control configurations, the Transmission Control Relay (if equipped) may be referred to as a PCM relay. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Right Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4897 Sensor - Line Pressure (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Description and Operation 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY - TRANSMISSION SOLENOID/PRESSURE SWITCH DESCRIPTION The Solenoid/Pressure Switch Assembly (1) is inside the transmission and mounted to the valve body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, OD, and UD friction elements (transmission clutches), and the torque converter clutch. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM. energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which allows fluid to pass through in their relaxed or "off" state. By design, this allows transmission limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM. during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM. relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM. detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM. for the correct states (open or closed) in each gear as shown in the following chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4900 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE DESCRIPTION The line pressure sensor (2) is mounted on the top of the valve body, next to the pressure control solenoid 0). The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4901 Fluid Pressure Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Line Pressure SENSOR-LINE PRESSURE DESCRIPTION The TCM utilizes a closed-loop system to control transmission line pressure. The system contains a variable force style solenoid, the Pressure Control Solenoid, mounted on the side of the solenoid and pressure switch assembly. The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump. The system also contains a variable pressure style sensor, the Line Pressure Sensor, which is a direct input to the TCM. The line pressure solenoid monitors the transmission line pressure and completes the feedback loop to the TCM. The TCM uses this information to adjust its control of the pressure control solenoid to achieve the desired line pressure. OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine. The TCM calculates the torque input to the transmission and uses that information as the primary input to the calculation. The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL positions. This is done to ensure consistent shift quality. During all other operation, the actual line pressure is compared to the desired line pressure and adjustments are made to the pressure control solenoid duty cycle. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4902 switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Fluid Pressure Sensor/Switch: Service and Repair 42RLE Automatic Transmission Assembly Transmission Solenoid/Pressure Switch ASSEMBLY TRANSMISSION SOLENOID/PRESSURE SWITCH REMOVAL NOTE: If the Solenoid/Pressure Switch Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Raise vehicle on hoist. 2. Remove valve body assembly from transmission. 3. Remove Solenoid/Pressure Switch Assembly retaining screws (2) from solenoid. 4. Remove Solenoid/Pressure Switch Assembly (1) and screen from valve body (2). INSTALLATION NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4905 1. Install Solenoid/Pressure Switch Assembly (1) and screen (3) to the separator and transfer plates. 2. Install and tighten retaining screws (2) to 5.5 Nm (50 inch lbs.) torque. 3. Install valve body. Sensor Variable Line Pressure SENSOR VARIABLE LINE PRESSURE REMOVAL 1. Remove the valve body from the transmission. 2. Remove the electrical connectors from the pressure control solenoid (1) and the line pressure sensor (2). 3. Remove the screws (6) holding the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 4. Remove the pressure control solenoid and line pressure sensor from the valve body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4906 INSTALLATION 1. Install the pressure control solenoid (1) and line pressure sensor (2) into the valve body. 2. Install the screws (6) to hold the pressure control solenoid (1) and line pressure sensor (2) to the valve body. 3. Install the electrical connectors to the pressure control solenoid (1) and the line pressure sensor (2). 4. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4907 Fluid Pressure Sensor/Switch: Service and Repair 45RFE/545RFE Automatic Transmission Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4908 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Sensor-Line Pressure SENSOR-LINE PRESSURE REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the line pres sure sensor (2). 4. Remove the bolt holding the line pressure sensor (2) to the transmission case. 5. Remove the line pressure sensor (2) from the transmission case. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4909 1. Install the line pressure sensor (2) into the transmission case. 2. Install the bolt to hold the line pressure sensor (2) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the line pressure sensor (2). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4913 Switch - Tow/Haul Overdrive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Overdrive Switch: Description and Operation 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4916 Overdrive Switch: Description and Operation 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE DESCRIPTION The tow/haul overdrive OFF (control) switch is located in the shift lever arm. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. OPERATION At key-on, overdrive operation is allowed. Pressing the switch once causes the tow/haul overdrive OFF mode to be entered and the Tow/Haul lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the tow/haul lamp to be turned off. The tow/haul overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the tow/haul overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Overdrive Switch: Service and Repair 42RLE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4919 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4920 Overdrive Switch: Service and Repair 45RFE/545RFE Automatic Transmission SWITCH-TOW/HAUL OVERDRIVE REMOVAL 1. Using a plastic trim tool, remove the tow/haul over drive off switch retainer (2) from the shift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1) INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul overdrive off switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul overdrive off switch (3) into the connector (2) 3. Push the tow/haul overdrive off switch (3) and wiring into the shift lever (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4921 4. Install the tow/haul overdrive off switch retainer onto the shift lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Shift Interlock Switch > Component Information > Locations > Page 4925 Switch - Clutch Interlock (M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 42RLE Automatic Transmission SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4930 Transmission Position Switch/Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Assembly-Transmission Solenoid/TRS ASSEMBLY-TRANSMISSION SOLENOID/TRS DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4931 The transmission solenoid/TRS assembly is internal to the transmission and mounted on the valve body assembly. The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control solenoid is located on the side of the solenoid/TRS assembly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM. OPERATION SOLENOIDS Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is controlled by line pressure and the position of the manual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, MultiSelect (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation. The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on five pressure switches to monitor fluid pressure in the L/R, 2C, 4C, UD and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The switches close at 2-3 psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES 45RFE PRESSURE SWITCH STATES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4932 545RFE PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Position Switch/Sensor: Service and Repair 42RLE Automatic Transmission SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4935 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4936 Transmission Position Switch/Sensor: Service and Repair 45RFE/545RFE Automatic Transmission ASSEMBLY-TRANSMISSION SOLENOID/TRS REMOVAL NOTE: If the Transmission Solenoid/TRS Assembly is being replaced, the Quick Learn Procedure must be performed. 1. Remove the valve body from the transmission. 2. Remove the bolts (1) holding the transmission solenoid/TRS assembly onto the valve body. 3. Separate the transmission solenoid/TRS assembly from the valve body. INSTALLATION 1. Place TRS selector plate in the PARK position. 2. Position the transmission solenoid/TRS assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4937 3. Install the bolts (1) to hold the transmission solenoid/TRS assembly onto the valve body. 4. Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 6 Nm (50 inch lbs.) . 5. Tighten the remainder of the solenoid assembly screws to 6 Nm (50 inch lbs.). 6. Install the valve body into the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Left Transmission (RFE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4941 Transmission Speed Sensor: Diagrams Sensor - Input Speed (RFE/RLE) Sensor - Output Speed (RFE/RLE) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Speed Sensor: Description and Operation 42RLE Automatic Transmission Sensor Output Speed SENSOR OUTPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor Input Speed SENSOR INPUT SPEED DESCRIPTION The Input (1) and Output (2) Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4944 OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4945 Transmission Speed Sensor: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Sensor-Output Speed SENSOR-OUTPUT SPEED DESCRIPTION The Input and Output Speed Sensors are two-wire magnetic pickup devices that generate AC signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM). OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed signals to determine the following: ^ Transmission gear ratio ^ Speed ratio error detection ^ CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following: ^ Torque converter clutch slippage ^ Torque converter element speed ratio Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission Transmission Speed Sensor: Service and Repair 42RLE Automatic Transmission Sensor Input Speed SENSOR INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor. NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor from the transmission case. INSTALLATION 1. Install the input speed sensor (1) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the input speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the input speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor Output Speed SENSOR OUTPUT SPEED REMOVAL 1. Raise vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4948 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the output speed sensor(2). NOTE: The speed sensor bolt has a sealing patch applied from the factory. Be sure to reuse the same bolt. 4. Remove the bolt holding the output speed sensor to the transmission case. 5. Remove the output speed sensor (2) from the transmission case. INSTALLATION 1. Install the output speed sensor (2) into the transmission case. NOTE: Before installing the speed sensor bolt, it will be necessary to replenish the sealing patch on the bolt using MOPAR Lock & Seal Adhesive. 2. Install the bolt to hold the output speed sensor into the transmission case. Tighten the bolt to 9 Nm (80 inch lbs.). 3. Install the wiring connector onto the output speed sensor 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4949 Transmission Speed Sensor: Service and Repair 45RFE/545RFE Automatic Transmission Sensor-Input Speed SENSOR-INPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. 3. Remove the wiring connector from the input speed sensor (3). 4. Remove the bolt holding the input speed sensor to the transmission case. 5. Remove the input speed sensor (3) from the trans mission case. INSTALLATION 1. Install the input speed sensor (3) into the transmission case. 2. Install the bolt to hold the input speed sensor (3) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the input speed sensor. 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Sensor-Output Speed SENSOR-OUTPUT SPEED REMOVAL 1. Raise vehicle. 2. Place a suitable fluid catch pan under the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 42RLE Automatic Transmission > Page 4950 3. Remove the wiring connector from the output speed sensor(1). 4. Remove the bolt holding the output speed sensor (1) to the transmission case. 5. Remove the output speed sensor (1) from the transmission case. INSTALLATION 1. Install the output speed sensor (1) into the transmission case. 2. Install the bolt to hold the output speed sensor (1) into the transmission case. Tighten the bolt to 12 Nm (105 inch lbs.). 3. Install the wiring connector onto the output speed sensor (1). 4. Verify the transmission fluid level. Add fluid as necessary. 5. Lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission Transmission Temperature Sensor/Switch: Description and Operation 42RLE Automatic Transmission Sensor Transmission Range SENSOR - TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) (2) is mounted to the top of the valve body inside the transmission and can only be serviced by removing the valve body assembly. The electrical connector extends through the transmission case. The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. TRS SWITCH STATES Sensor Transmission Temperature SENSOR TRANSMISSION TEMPERATURE DESCRIPTION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4955 The transmission temperature sensor (2) is located in the transmission range sensor (1) and communicates transmission sump temperature to the TCM. OPERATION The transmission range sensor (TRS) has an integrated thermistor that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and converter lock up, the TCM requires this information to determine which shift schedule to operate in. The TCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > 42RLE Automatic Transmission > Page 4956 Transmission Temperature Sensor/Switch: Description and Operation 45RFE/545RFE Automatic Transmission Sensor-Transmission Temperature SENSOR-TRANSMISSION TEMPERATURE DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Range Sensor (TRS). OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In gear run time since start-up Sensor-Transmission Range SENSOR-TRANSMISSION RANGE DESCRIPTION The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission. The Transmission Range Sensor (TRS) has five switch contact pins that: ^ Determine shift lever position ^ Supply ground to the Starter ^ Relay in Park and Neutral only. ^ Supply +12 V to the backup lamps in Reverse only. The TRS also has an integrated temperature sensor (thermistor) that communicates transmission temperature to the TCM and PCM. OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as "between gear" codes. This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4957 Transmission Temperature Sensor/Switch: Service and Repair SENSOR TRANSMISSION RANGE REMOVAL 1. Remove valve body assembly from vehicle. 2. Remove the manual shaft seal (1). 3. Remove manual shaft/TRS retaining screw (1). 4. Slide TRS off of manual valve shaft. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4958 1. Install the TRS (2) to the manual shaft. Make sure TRS locating pin rests in manual valve bore slot. 2. Install the TRS/manual shaft retaining screw (1) and torque to 5 Nm (45 inch lbs.) torque. 3. Install the manual shaft seal (1). 4. Install valve body to the transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Antilock Brake System ABS Light: Description and Operation Antilock Brake System An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > Antilock Brake System > Page 4965 ABS Light: Description and Operation Electronic Stability Program/Brake Assist System Indicator An ESP/BAS indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional Electronic Stability Program (ESP)/Brake Assist System (BAS), this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. The ESP/BAS indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/ Brake Assist System (BAS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is illuminated for about four seconds as a bulb test. - ESP/BAS Lamp-On Message - Each time the cluster receives an ESP/BAS lamp-on message from the CAB or the TIPM, the ESP/BAS indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the CAB or TIPM message. The indicator remains illuminated until the cluster receives an ESP/BAS lamp-off message from the CAB or TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and TIPM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or TIPM then sends the proper ESP/BAS lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the ESP/ BAS system, the CAB, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ESP/BAS indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement Technical Service Bulletin # F05 Date: 060701 Recall - ABS Control Module Replacement Revised July 2006 Dealer Service Instructions for: Safety Recall F05 Antilock Brake System Control Module Please remove and discard from your files all previous copies of Safety Recall F05 (dated June 2006). This revision has additional parts information to clarify the ABS Control Module application for Dodge Ram Mega Cab models. Models 2006 (DR) Dodge Ram Pickup Truck (1500 Series) 2006 (DH) Dodge Ram Pickup Truck (1500 Mega Cab & 2500 Series) 2006 (D1) Dodge Ram Pickup Truck (3500 Series) 2006 (ND) Dodge Dakota Pickup Truck NOTE: This recall applies only to the above vehicles equipped with a Four-Wheel Antilock Brake System (sales code BGK or BRT) built from September 12, 2005 through December 11, 2005 (MDH 091221 through 121114). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Antilock Brake System (ABS) control module on about 37,900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be replaced and initialized with the StarSCAN tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4974 Parts Information The ABS module part number for the vehicle to be serviced may also be determined as follows: > From the DealerCONNECT "Service" tab, in the "Write Up" box under "Vehicle Information Plus" select "Single VIN Inquiry." Enter the VIN and odometer reading and click the "View" button. Select the Recall Tab and the recall part number will be displayed. > From the DealerCONNECT "Service" tab, select "Global Recall System." Click on the recall number, select "List by VIN" from drop down menu, and click the "Submit" button. A list of incomplete involved vehicles for your dealer will be generated. NOTE: If F05 is not listed, there are no involved vehicles assigned to your dealer code. Special Tools Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4975 The existing special tools shown will be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4976 schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: The StarSCAN must be used to initialize the new ABS control module after installation. 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Clean the ABS control module to prevent dirt from falling into the hydraulic control unit when the ABS control module is removed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4977 NOTE: The ABS control module is located next to the battery on DR/DH and D1 models (Dodge Ram Truck) (Figure 1). The ABS control module is located under the Power Distribution Center on ND models (Dodge Dakota) (Figure 2). 3. Pull up on the ABS control module harness connector lock and disconnect the wiring from the ABS control module (Figure 1). 4. Using a T-20 Torx driver, remove and discard the ABS control module mounting screws (Figure 3). 5. Remove and discard the ABS control module from the Hydraulic Control Unit (HCU). 6. Install the new ABS control module onto the HCU. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4978 7. Install the new ABS control module mounting screws included in the kit (Figure 4). Tighten the screws to 35 in. lbs. (4 N.m). 8. Connect the wiring harness to the ABS control module and push down on the connector lock to secure the connector. 9. Connect the negative battery cable(s) to the negative battery terminal(s). 10. Connect the StarSCAN to the data link connector located under the steering column. 11. Place the ignition key in the "RUN" position (engine not running). 12. Push the power button on the StarSCAN and wait for the scan tool to "power up." 13. From the Home Screen, select "ECU¡ VIEW". 14. Select "ABS Anti-lock Brakes / Electronic Stability". 15. Select "Misc. Functions" on the screen. 16. Select "Initialize ECU" and then press the "START" button. 17. Press the "NEXT" button. 18. Follow the scan tool screen prompts to complete the ECU initializing process. 19. Select the "BACK" button twice. 20. After completing ABS control module reprogramming clear all fault codes using the following procedure: a. Return to the "Main Menu" (Home Page) and select "System View". b. Select "All DTC's" c. Select "Clear All Stored DTC's" and then follow the screen prompts. 21. Remove the StarSCAN from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4979 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA06V038000 > Feb > 06 > Recall 06V038000: ABS ECU Replacement Electronic Brake Control Module: Recalls Recall 06V038000: ABS ECU Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2006 Dodge/Ram 2006 Mitsubishi/Raider 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V038000 MFG'S REPORT DATE: February 07, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 39274 SUMMARY: On certain pickup trucks equipped with four-wheel Antilock Brake Systems (ABS), The ABS Electronic Control Unit (ECU) may cause a loss of front to rear brake balance, and the rear brakes could lock up prematurely during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the ABS ECU. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F05. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement Technical Service Bulletin # F05 Date: 060701 Recall - ABS Control Module Replacement Revised July 2006 Dealer Service Instructions for: Safety Recall F05 Antilock Brake System Control Module Please remove and discard from your files all previous copies of Safety Recall F05 (dated June 2006). This revision has additional parts information to clarify the ABS Control Module application for Dodge Ram Mega Cab models. Models 2006 (DR) Dodge Ram Pickup Truck (1500 Series) 2006 (DH) Dodge Ram Pickup Truck (1500 Mega Cab & 2500 Series) 2006 (D1) Dodge Ram Pickup Truck (3500 Series) 2006 (ND) Dodge Dakota Pickup Truck NOTE: This recall applies only to the above vehicles equipped with a Four-Wheel Antilock Brake System (sales code BGK or BRT) built from September 12, 2005 through December 11, 2005 (MDH 091221 through 121114). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Antilock Brake System (ABS) control module on about 37,900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be replaced and initialized with the StarSCAN tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4989 Parts Information The ABS module part number for the vehicle to be serviced may also be determined as follows: > From the DealerCONNECT "Service" tab, in the "Write Up" box under "Vehicle Information Plus" select "Single VIN Inquiry." Enter the VIN and odometer reading and click the "View" button. Select the Recall Tab and the recall part number will be displayed. > From the DealerCONNECT "Service" tab, select "Global Recall System." Click on the recall number, select "List by VIN" from drop down menu, and click the "Submit" button. A list of incomplete involved vehicles for your dealer will be generated. NOTE: If F05 is not listed, there are no involved vehicles assigned to your dealer code. Special Tools Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4990 The existing special tools shown will be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4991 schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: The StarSCAN must be used to initialize the new ABS control module after installation. 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Clean the ABS control module to prevent dirt from falling into the hydraulic control unit when the ABS control module is removed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4992 NOTE: The ABS control module is located next to the battery on DR/DH and D1 models (Dodge Ram Truck) (Figure 1). The ABS control module is located under the Power Distribution Center on ND models (Dodge Dakota) (Figure 2). 3. Pull up on the ABS control module harness connector lock and disconnect the wiring from the ABS control module (Figure 1). 4. Using a T-20 Torx driver, remove and discard the ABS control module mounting screws (Figure 3). 5. Remove and discard the ABS control module from the Hydraulic Control Unit (HCU). 6. Install the new ABS control module onto the HCU. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4993 7. Install the new ABS control module mounting screws included in the kit (Figure 4). Tighten the screws to 35 in. lbs. (4 N.m). 8. Connect the wiring harness to the ABS control module and push down on the connector lock to secure the connector. 9. Connect the negative battery cable(s) to the negative battery terminal(s). 10. Connect the StarSCAN to the data link connector located under the steering column. 11. Place the ignition key in the "RUN" position (engine not running). 12. Push the power button on the StarSCAN and wait for the scan tool to "power up." 13. From the Home Screen, select "ECU¡ VIEW". 14. Select "ABS Anti-lock Brakes / Electronic Stability". 15. Select "Misc. Functions" on the screen. 16. Select "Initialize ECU" and then press the "START" button. 17. Press the "NEXT" button. 18. Follow the scan tool screen prompts to complete the ECU initializing process. 19. Select the "BACK" button twice. 20. After completing ABS control module reprogramming clear all fault codes using the following procedure: a. Return to the "Main Menu" (Home Page) and select "System View". b. Select "All DTC's" c. Select "Clear All Stored DTC's" and then follow the screen prompts. 21. Remove the StarSCAN from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 4994 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA06V038000 > Feb > 06 > Recall 06V038000: ABS ECU Replacement Electronic Brake Control Module: All Technical Service Bulletins Recall 06V038000: ABS ECU Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2006 Dodge/Ram 2006 Mitsubishi/Raider 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V038000 MFG'S REPORT DATE: February 07, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 39274 SUMMARY: On certain pickup trucks equipped with four-wheel Antilock Brake Systems (ABS), The ABS Electronic Control Unit (ECU) may cause a loss of front to rear brake balance, and the rear brakes could lock up prematurely during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the ABS ECU. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F05. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 4999 Electronic Brake Control Module: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5000 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5001 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5002 Electronic Brake Control Module: Diagrams Module - Anti-lock Brakes (RWAL) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5003 Module - Anti-lock Brakes (AWAL) Module - Brake Provision Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5004 Electronic Brake Control Module: Description and Operation The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5005 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 N.m (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The HCU (3) consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the ABM. The valves modulate brake pressure during antilock braking and are controlled by the ABM. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. NOTE: The three modes mentioned below do occur but not necessarily in the order listed every time. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the ABM closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the ABM closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The ABM maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply the brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) HCU (HYDRAULIC CONTROL UNIT) REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connectors. 4. Remove the brake lines from the HCU (3). 5. Remove HCU/ABM mounting bolts (1) and remove the HCU/ABM (3) from the battery tray (4). INSTALLATION NOTE: If the ABM (2) is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install HCU/ABM (3) on the mounts to the battery tray (4) and Tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the HCU (3) and tighten to 19 Nm (170 inch lbs.). 3. Install the electrical harness connectors to the HCU/ABM (3) and push down on the release to secure the connectors. 4. Install the battery 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) > Page 5011 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve VALVE-RWAL REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connector. 4. Remove the brake lines from the RWAL valve (1). 5. Remove RWAL valve mounting nuts (2) and remove the RWAL valve (1). INSTALLATION 1. Install RWAL valve (1) and Tighten the nuts (2) to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the RWAL valve and tighten to 19 Nm (170 inch lbs.). 3. Install the electrical harness connector to the RWAL valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator Traction Control Indicator Lamp: Description and Operation Electronic Stability Program/Brake Assist System Indicator An ESP/BAS indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional Electronic Stability Program (ESP)/Brake Assist System (BAS), this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. The ESP/BAS indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/ Brake Assist System (BAS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is illuminated for about four seconds as a bulb test. - ESP/BAS Lamp-On Message - Each time the cluster receives an ESP/BAS lamp-on message from the CAB or the TIPM, the ESP/BAS indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the CAB or TIPM message. The indicator remains illuminated until the cluster receives an ESP/BAS lamp-off message from the CAB or TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and TIPM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or TIPM then sends the proper ESP/BAS lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the ESP/ BAS system, the CAB, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ESP/BAS indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 5016 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator TRACTION CONTROL INDICATOR A traction control indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional Traction Control System (TCS), this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The traction control indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Stability - Anti-Spin" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The traction control indicator is serviced as a unit with the instrument cluster. The traction control indicator gives an indication to the vehicle operator when the electronic Traction Control System (TCS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The traction control indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the traction control indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the traction control indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Traction Control Lamp-On Message - Each time the cluster receives a traction control lamp-on message from the CAB indicating that the TCS has been activated, the traction control indicator will be illuminated. The indicator remains illuminated until the cluster receives a traction control lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the traction control indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB continually monitors the traction control switch to determine the proper outputs to the components of the Antilock Brake System (ABS). The CAB then sends the proper traction control lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the traction control indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the traction control switch, the ABS, the CAB, the CAN data bus, or the electronic message inputs to the instrument cluster that control the traction control indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5020 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5021 Rear Chassis Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5022 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed - ABS - Left Front Sensor-Wheel Speed - ABS - Rear Sensor-Wheel Speed - ABS - Right Front Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5023 Wheel Speed Sensor: Description and Operation SENSOR- WHEEL SPEED-ABS-FRONT DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal. ^ Number of windings in the sensor; more windings provide a stronger signal. ^ Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be. ^ Distance (3) air gap between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a Rolls Test on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear Wheel Speed Sensor: Testing and Inspection Rear REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear > Page 5026 Wheel Speed Sensor: Testing and Inspection Tone Wheel-Rear WHEEL-TONE REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The ABM monitors the system inputs and outputs circuits to verify the system is operating properly. If the ABM senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool must be used to diagnose the Antilock Brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front SENSOR- WHEEL SPEED-ABS-FRONT REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5029 Wheel Speed Sensor: Service and Repair Rear SENSOR-WHEEL SPEED-ABS-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5034 Brake Bleeding: Service and Repair Base Brake System MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5035 Brake Bleeding: Service and Repair Antilock Brake System ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5036 Brake Bleeding: Service and Repair Hydraulic Brake Booster BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation Brake Pedal Assy: Description and Operation PEDAL DESCRIPTION NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot shaft pin (3) and bushings (2). If the bushings (2) become dry a spray lubricant can be used to eliminate noises. The booster push rod is attached to the pedal with a clip (1). The pedal (4), bushings (2), pivot pin (3) and support bracket are not serviceable components. OPERATION The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod is depressed which moves the booster secondary rod. The booster secondary rod depress the master cylinder piston. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 5040 Brake Pedal Assy: Service and Repair PEDAL REMOVAL NOTE: The brake pedal is serviced as a complete assembly including accelerator pedal and the bracket. 1. Disconnect the negative battery cable. 2. Remove the steering column opening cover. 3. Remove the brake lamp switch and discard. 4. On vehicles equipped with adjustable pedals. Disconnect the adjuster cable (1) to the pedal (2). 5. Remove the steering column. 6. Remove the brake booster (5). 7. Disconnect the electrical connectors. 8. Remove the module mounting bolts. 9. Disconnect the accelerator pedal cable. 10. Remove the pedal assembly mounting nuts/fasteners (4). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Page 5041 1. Install the pedal assembly (4) to the vehicle. 2. Install the mounting bolts (3) and tighten to 28 Nm (21 ft. lbs.). 3. Reconnect the accelerator cable (1) to the pedal (2). 4. Install the module mounting bolts and tighten to 38 Nm (28 ft. lbs.). 5. Reconnect the electrical connectors. 6. Install the brake booster. 7. Install the steering column. 8. Install a new brake lamp switch. 9. On vehicles equipped with adjustable brake pedal. Reconnect the electrical connector to the motor and the adjuster cable at the pedal. 10. Install the steering column opening cover. 11. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation Brake Caliper: Description and Operation CALIPERS-DISC BRAKE DESCRIPTION LIGHT DUTY (LD) CALIPERS NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. The calipers are a dual piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. HEAVY DUTY (HD) CALIPERS The calipers are a dual piston type in the front & rear. The calipers are free to slide laterally, this allows continuous compensation for lining wear. FRONT CALIPERS - SRT10 The front calipers (1) are a four piston type and the rear calipers are a dual piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION DISC BRAKE CALIPER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Page 5046 When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Light Duty (LD) Calipers FRONT-LD REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly 3. Compress the disc brake caliper (6). 4. Remove the banjo bolt (4) and discard the copper washers. 5. Remove the caliper slide pin bolts (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5049 6. Remove the disc brake caliper (1) from the caliper adapter (2). 7. Remove the caliper slide pins from the adapter. DISASSEMBLY 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5050 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) by hand. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5051 CAUTION: Do not scratch piston bore while removing the seals. 9. Remove the lip seal from the groove (4) with a pick tool (3). 10. Remove piston seals (2) from caliper (1) by hand. ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5052 NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (2) into caliper bores (1). 3. Leave boot (1) dry and slip onto end of piston (2). NOTE: The dust boot lip must be inserted before the piston 4. Slightly pull out lip portion of piston boot (3) so it protrudes past the bottom of the piston (2) and work lip into outermost groove on caliper housing M. 5. Carefully press the lip (3) into the groove with a suitable tool (4) Avoid using sharp-edged tools This will ensure that the lip is nested into the groove all around before pushing the piston into the bore. 6. Press the piston fully into the bore using special tool C3716-A seal installer (3) with C-4171 Handle M. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5053 7. Once the piston is pressed into the bottom of the bore, Check to see that the dust boot bellows are not inflated with air. If needed, push in between the dust boot and piston to expel any trapped air. INSTALLATION NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-8079 grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). NOTE: Install a new copper washers on the banjo bolt when installing 4. Install the disc brake caliper (1) to the brake caliper adapter (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5054 5. Install the banjo bolt (4) with new copper washers to the caliper (6). Tighten to 28 Nm (250 inch lbs.). 6. Install the caliper slide pin bolts (2). Tighten to 32 Nm (24 ft. lbs.). 7. Bleed the base brake system. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Heavy Duty (HD) Calipers FRONT-HD REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly 3. Compress the disc brake caliper. 4. Remove the banjo bolt and discard the copper washer. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper. DISASSEMBLY 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5055 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5056 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5057 NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): ^ 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning 807 grease only CAUTION: Use of alternative grease may cause damage to the boots seals. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. INSTALLATION NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper. CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.). 3. Install the caliper slide pin bolts. tighten to 32 Nm (24 ft. lbs.). 4. Bleed the base brake system. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Disc Brake Caliper Adapter ADAPTER-DISC BRAKE CALIPER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5058 FRONT REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove the caliper slide pin bolts (4). 4. Remove the disc brake caliper (1) from the adapter (2). CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5059 5. Remove the inboard (4) and outboard (2) brake pads. 6. Remove the caliper adapter mounting bolts (5). 7. Remove the caliper slide pins from the adapter. INSTALLATION NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only a Non-Petroleum based grease, such as Dow Corning-8079 grease. NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-807 grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5060 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). 4. Install the caliper adapter mounting bolts (5). Tighten the mounting bolts to 176 Nm (130 ft. lbs). 5. Install the inboard (4) and outboard (2) pads. 6. Install the caliper (2) and the caliper slide pin bolts (4). 7. Install the tire and wheel assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5061 Brake Caliper: Service and Repair Rear LD and HD Calipers REAR LD AND HD CALIPERS REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support vehicle. 2. Remove the wheel and tire assembly 3. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 4. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 5. Remove the caliper slide bolts (3). 6. Remove the caliper (6) from vehicle. INSTALLATION 1. Install caliper (6) to the caliper adapter (1). 2. Coat the caliper mounting slide pin bolts (3) with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose (4) to the caliper (6) with new seal washers and tighten fitting bolt to 27 Nm (245 inch lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Bleed the base brake system. 6. Install the wheel and tire assemblies. 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle. Disc Brake Caliper Adapter ADAPTER-DISC BRAKE CALIPER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5062 REAR REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). 10. Remove the caliper adapter (1). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5063 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft. lbs) LID or tighten to 197 Nm (145 ft. lbs.) HID. 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly Mount-Disc Brake Caliper Adapter MOUNT-DISC BRAKE CALIPER ADAPTER REMOVAL 1. Remove wheel and tire assembly 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (3) attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount (1) from the axle housing (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5064 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate on axle flange. Tighten attaching bolts (3) to 68 Nm (50 ft. lbs.) LD or tighten to 203 Nm (150 ft. lbs.) HD. 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front LD PADS - BRAKE REMOVAL LD 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper (2). 4. Remove the caliper slide pin bolts (4). 5. Remove the caliper (1) from the caliper adapter (2). NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5069 7. Remove the inboard brake pad (4) from the caliper adapter (1). 8. Remove the outboard brake pad (2) from the caliper adapter (1). 9. Remove the anti-rattle clips (1) from the pad (2). INSTALLATION 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper mounting adapter. 3. Install new anti-rattle clips (1) to the brake pads (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5070 4. Install inboard brake pad (4) in adapter (1). 5. Install outboard brake pad (2) in adapter (1). 6. Install the caliper (1) over rotor, Then push the caliper onto the adapter (2). 7. Install caliper slide pin bolts (4). 8. Install wheel and tire assemblies and lower vehicle. 9. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 10. Top off master cylinder fluid level. HD PADS - BRAKE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5071 REMOVAL HD 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper. 4. Remove the caliper. 5. Remove the caliper by tilting the top up and off the caliper adapter. NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper. 7. Remove the inboard brake shoe (1) from the caliper adapter (2). 8. Remove the outboard brake shoe (1) from the caliper adapter (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5072 NOTE: Anti-rattle springs are not interchangeable. 9. Remove the top anti-rattle springs (2) from the caliper adapter (1). 10. Remove the bottom anti-rattle springs (2) from the caliper adapter (1). INSTALLATION 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper mounting adapter (1) and anti-rattle springs (2). 3. Lubricate anti-rattle springs with Mopar brake grease. NOTE: Anti-rattle springs are not interchangeable. 4. Install new top anti-rattle springs (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5073 5. Install new bottom anti-rattle springs (1). 6. Install inboard brake shoe (1) in adapter (2). 7. Install outboard brake shoe (1) in adapter (2). 8. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 9. Install caliper. 10. Install wheel and tire assemblies and lower vehicle. 11. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 12. Top off master cylinder fluid level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5074 Brake Pad: Service and Repair Rear PADS - BRAKE REMOVAL 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assemblies. 3. Compress the caliper. 4. Remove caliper slide bolts (3). NOTE: Do not allow brake hose to support caliper assembly. 5. Remove the caliper (3) and then tilt the top up and off the caliper adapter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5075 6. Remove inboard brake shoe (1) from the caliper adapter (2). 7. Remove outboard brake shoe (1) from caliper adapter (2). NOTE: Anti-rattle springs are not interchangeable. 8. Remove the top anti-rattle spring (2) from the caliper adapter (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5076 9. Remove the bottom anti-rattle spring (2) from the caliper adapter (1). INSTALLATION 1. Clean caliper mounting adapter (1) and anti-rattle springs (2). 2. Lubricate anti-rattle springs with Mopar brake grease. NOTE: Anti-rattle springs are not interchangeable. 3. Install new top anti-rattle spring (2). 4. Install new bottom anti-rattle spring (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5077 5. Install inboard brake shoe (1) in adapter (2). 6. Install outboard brake shoe (1) in adapter (2). 7. Tilt the bottom of the caliper (3) over rotor (1) and under adapter. Then push the top of the caliper down onto the adapter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5078 8. Install caliper (6). 9. Install wheel and tire assemblies and lower vehicle. 10. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 11. Top off master cylinder fluid level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications Front/Rear Disc Brake Rotor Maximum Runout LD ........................................................................................................................... ......................................... 0.050 mm (0.002 inch) Front Disc Brake Rotor Maximum Runout SRT-10 ............................................................................................................................................................. 0.050 mm (0.002 inch) Rear Disc Brake Rotor Maximum Runout SRT-10 ............................................................................................................................................................. 0.050 mm (0.002 inch) Front/Rear Disc Brake Rotor Maximum Runout HD SRW ................................................................................................................................................ 0.131 mm (0.005 inch) Rear Disc Brake Rotor Maximum Runout HD DRW ......................................................................................................................................................... 0.328 mm (0.012 inch) Front/Rear Disc Brake Rotor Maximum Thickness Variation LD ................................................................................................................................... 0.012 mm (0.0005 inch) Front Disc Brake Rotor Maximum Thickness Variation SRT-10 ...................................................................................................................................... 0.012 mm (0.0005 inch) Rear Disc Brake Rotor Maximum Thickness Variation SRT-10 ...................................................................................................................................... 0.012 mm (0.0005 inch) Front/Rear Disc Brake Rotor Maximum Thickness Variation Loose Rotor HD ........................................................................................................................ 0.013 mm (0.0005 inch) Minimum Front Rotor Thickness LD ........................................................................................................................................................ ............................................ 26.4 mm (1.039 inch) SRT-10 ................................................................ ............................................................................................................................ 33.9 mm (1.344 inch) HD ............................................................................................................................................... ......................................................... 34 mm (1.33 inch) Minimum Rear Rotor Thickness LD ........................................................................................................................................................ ............................................ 20.4 mm (0.803 inch) HD ....................................................................... .......................................................................................................................... 28.39 mm (1.117 inch) SRT-10 ....................................................................................................................................... ..................................................... 28.4 mm (1.118 inch) Rear Disc Brake Rotor Max Drum Diameter SRT-10 & HD .............................................................................................................................................. 207.2 mm (8.157 inch) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5082 Brake Rotor/Disc: Testing and Inspection DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining with a disc brake lathe if surface scoring and wear are light. Replace the rotor for the following conditions: ^ Severely Scored ^ Tapered ^ Hard Spots ^ Cracked ^ Below Minimum Thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Check rotor lateral runout with dial indicator C-3339 (1). Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 inch) inward from the rotor edge. NOTE: Be sure wheel bearing has zero end play before checking rotor runout. Maximum allowable rotor runout is 0.131 mm (0.005 inch) HD. Maximum allowable rotor runout is 0.050 mm (0.002 inch) LD. ROTOR THICKNESS VARIATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5083 Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer (1) approximately 25.4 mm (1 inch) from the rotor (2) outer circumference for each measurement. Thickness should not vary by more than 0.015 mm (0.0059 inch) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front Brake Rotor/Disc: Service and Repair Front Front - LD ROTORS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the caliper (1) with the adaptor bolts (5) from the steering knuckle (4) and remove caliper adapter assembly (1). NOTE: Do not allow brake hose to support caliper adapter assembly (1). 4. Remove the rotor (2) from the hub/bearing (3). INSTALLATION 1. Install the rotor (2) onto the hub/bearing (3). 2. Install the caliper adapter assembly (1) and tighten adapter bolts (5) to 176 Nm (130 ft. lbs.). 3. Install the wheel and tire assembly and lower the vehicle. 4. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Front - HD ROTORS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 5086 NOTE: Do not allow brake hose to support caliper adapter assembly. 3. Remove the caliper from the steering knuckle and remove caliper adapter assembly. 4. Remove the extension to the rotor nuts (HD DRW ONLY). 5. Remove the rotor from the hub/bearing wheel studs. INSTALLATION 1. Install the hub extension and nuts to the front rotor. Tighten nuts to 130 Nm (96 ft. lbs) (HD DRW ONLY). 2. Install the rotor onto the hub/bearing wheel studs. 3. Install the caliper adapter assembly and tighten adapter bolts. 4. Install the wheel and tire assembly and lower the vehicle. 5. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 5087 Brake Rotor/Disc: Service and Repair Rear Single Rear Wheels ROTORS REMOVAL 1. Raise and support the vehicle 2. Remove the tire and wheel assembly 3. Remove the disc brake caliper (3). 4. Remove the caliper adapter (2) bolts. 5. Remove the retaining clips and rotor assembly (1). INSTALLATION 1. Install the rotor (1) to the axle shaft. 2. Install the caliper adapter (2). 3. Install the caliper adapter bolts and tighten the mounting bolts to 135 Nm (100 ft. lbs) LD or 197 Nm (145 ft. lbs) HD. 4. Install the disc brake caliper (3). 5. Install the tire and wheel assembly. 6. Lower the vehicle. Dual Rear Wheels ROTORS REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Front > Page 5088 1. Raise and support the vehicle 2. Remove the tire and wheel assembly 3. Remove the disc brake caliper. 4. Remove the caliper adapter bolts. 5. Remove the rear axle shaft from the housing on dual rear wheels. 6. Remove the hub and rotor assembly (C3500 only). INSTALLATION 1. Install the hub to the rotor. Tighten the bolts (1) to 128 Nm (95 ft. lbs.). 2. Install the hub and rotor assembly. 3. Install the rear axle shaft to the housing with dual wheels. 4. Install the caliper adapter bolts 197 Nm (145 ft. lbs) LD 5. Install the disc brake caliper. 6. Install the tire and wheel assembly. 7. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5094 Brake Bleeding: Service and Repair Base Brake System MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down close the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5095 Brake Bleeding: Service and Repair Antilock Brake System ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the DRB scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5096 Brake Bleeding: Service and Repair Hydraulic Brake Booster BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation Brake Caliper: Description and Operation CALIPERS-DISC BRAKE DESCRIPTION LIGHT DUTY (LD) CALIPERS NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. The calipers are a dual piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. HEAVY DUTY (HD) CALIPERS The calipers are a dual piston type in the front & rear. The calipers are free to slide laterally, this allows continuous compensation for lining wear. FRONT CALIPERS - SRT10 The front calipers (1) are a four piston type and the rear calipers are a dual piston type. The calipers are free to slide laterally, this allows continuous compensation for lining wear. OPERATION DISC BRAKE CALIPER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Page 5100 When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement (6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Light Duty (LD) Calipers FRONT-LD REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose with result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly 3. Compress the disc brake caliper (6). 4. Remove the banjo bolt (4) and discard the copper washers. 5. Remove the caliper slide pin bolts (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5103 6. Remove the disc brake caliper (1) from the caliper adapter (2). 7. Remove the caliper slide pins from the adapter. DISASSEMBLY 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5104 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) by hand. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5105 CAUTION: Do not scratch piston bore while removing the seals. 9. Remove the lip seal from the groove (4) with a pick tool (3). 10. Remove piston seals (2) from caliper (1) by hand. ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5106 NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (2) into caliper bores (1). 3. Leave boot (1) dry and slip onto end of piston (2). NOTE: The dust boot lip must be inserted before the piston 4. Slightly pull out lip portion of piston boot (3) so it protrudes past the bottom of the piston (2) and work lip into outermost groove on caliper housing M. 5. Carefully press the lip (3) into the groove with a suitable tool (4) Avoid using sharp-edged tools This will ensure that the lip is nested into the groove all around before pushing the piston into the bore. 6. Press the piston fully into the bore using special tool C3716-A seal installer (3) with C-4171 Handle M. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5107 7. Once the piston is pressed into the bottom of the bore, Check to see that the dust boot bellows are not inflated with air. If needed, push in between the dust boot and piston to expel any trapped air. INSTALLATION NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only Non-Petroleum based grease. NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-8079 grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). NOTE: Install a new copper washers on the banjo bolt when installing 4. Install the disc brake caliper (1) to the brake caliper adapter (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5108 5. Install the banjo bolt (4) with new copper washers to the caliper (6). Tighten to 28 Nm (250 inch lbs.). 6. Install the caliper slide pin bolts (2). Tighten to 32 Nm (24 ft. lbs.). 7. Bleed the base brake system. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Heavy Duty (HD) Calipers FRONT-HD REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly 3. Compress the disc brake caliper. 4. Remove the banjo bolt and discard the copper washer. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper. DISASSEMBLY 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5109 3. Take another piece of wood and pad it with one inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: NEVER ATTEMPT TO CATCH THE PISTON AS IT LEAVES THE BORE. THIS COULD RESULT IN PERSONAL INJURY. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5110 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). ASSEMBLY CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5111 NOTE: Verify seal is fully seated and not twisted. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): ^ 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning 807 grease only CAUTION: Use of alternative grease may cause damage to the boots seals. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. INSTALLATION NOTE: Install a new copper washers on the banjo bolt when installing 1. Install the disc brake caliper. CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt with new copper washers to the caliper. Tighten to 27 Nm (20 ft. lbs.). 3. Install the caliper slide pin bolts. tighten to 32 Nm (24 ft. lbs.). 4. Bleed the base brake system. 5. Install the tire and wheel assembly. 6. Lower the vehicle. Disc Brake Caliper Adapter ADAPTER-DISC BRAKE CALIPER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5112 FRONT REMOVAL 1. Raise and support the vehicle. 2. Remove the front wheel and tire assembly. 3. Remove the caliper slide pin bolts (4). 4. Remove the disc brake caliper (1) from the adapter (2). CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5113 5. Remove the inboard (4) and outboard (2) brake pads. 6. Remove the caliper adapter mounting bolts (5). 7. Remove the caliper slide pins from the adapter. INSTALLATION NOTE: Petroleum based grease should not be used on any of the rubber components of the caliper, Use only a Non-Petroleum based grease, such as Dow Corning-8079 grease. NOTE: Clean slide pin bores thoroughly to remove any old grease. NOTE: Use grease packets included with kit or Dow Corning-807 grease. 1. Thoroughly coat the new slide pins (3) on all working surfaces. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5114 2. Install the boot (2) onto the slide pin (3) and then insert into the adapter (1). 3. Push the pin (3) all the way into the adapter (1) and carefully expel the trapped air by gently pushing on the boot (2) near the slide pin head (3). 4. Install the caliper adapter mounting bolts (5). Tighten the mounting bolts to 176 Nm (130 ft. lbs). 5. Install the inboard (4) and outboard (2) pads. 6. Install the caliper (2) and the caliper slide pin bolts (4). 7. Install the tire and wheel assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5115 Brake Caliper: Service and Repair Rear LD and HD Calipers REAR LD AND HD CALIPERS REMOVAL CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Raise and support vehicle. 2. Remove the wheel and tire assembly 3. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 4. Remove the brake hose banjo bolt and discard the copper washers if replacing caliper. 5. Remove the caliper slide bolts (3). 6. Remove the caliper (6) from vehicle. INSTALLATION 1. Install caliper (6) to the caliper adapter (1). 2. Coat the caliper mounting slide pin bolts (3) with silicone grease. Then install and tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the brake hose banjo bolt if removed. 4. Install the brake hose (4) to the caliper (6) with new seal washers and tighten fitting bolt to 27 Nm (245 inch lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. 5. Bleed the base brake system. 6. Install the wheel and tire assemblies. 7. Remove the supports and lower the vehicle. 8. Verify a firm pedal before moving the vehicle. Disc Brake Caliper Adapter ADAPTER-DISC BRAKE CALIPER Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5116 REAR REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper slide bolts. 6. Remove the disc brake caliper from the mount. CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). 10. Remove the caliper adapter (1). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5117 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft. lbs) LID or tighten to 197 Nm (145 ft. lbs.) HID. 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly Mount-Disc Brake Caliper Adapter MOUNT-DISC BRAKE CALIPER ADAPTER REMOVAL 1. Remove wheel and tire assembly 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (3) attaching the support plate to the axle and remove the support plate. 9. Remove the caliper adapter mount (1) from the axle housing (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5118 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate on axle flange. Tighten attaching bolts (3) to 68 Nm (50 ft. lbs.) LD or tighten to 203 Nm (150 ft. lbs.) HD. 3. Install parking brake cable in the brake lever. 4. Install the park brake shoes. 5. Install axle shaft. 6. Adjust brake shoes to drum with brake gauge. 7. Install the rotor. 8. Install the caliper adapter. 9. Install the caliper. 10. Install wheel and tire assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5123 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5124 Brake Fluid: Specifications Hydraulic Brake Fluid Type ............................................................................................................................................... Mopar DOT 3 and SAE J1703 Note: If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5125 Brake Fluid: Description and Operation BRAKE FLUID DESCRIPTION The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from an container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5126 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5127 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5131 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5132 Sensor - Brake Fluid Level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring Brake Hose/Line: Service and Repair Flaring DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. ISO FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. To make a ISO flare use an ISO flaring tool kit. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. 4. Position the tube in the flaring tool flush with the top of the tool bar (6). Then tighten the tool bar on the tube. 5. Install the correct size adaptor (1) on the flaring tool yoke screw. 6. Lubricate the adaptor (2). 7. Align the adaptor and yoke screw over the tube. 8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring > Page 5137 Brake Hose/Line: Service and Repair Rear Tube / Hose Assembly REAR TUBE / HOSE ASSEMBLY REMOVAL 1. Raise and support the vehicle. 2. Remove the brake line located at the axle. 3. Remove the mounting bolt (2) for the brake hose (3) at the axle. 4. Remove the banjo bolt (1) at the caliper. 5. Remove the hose. INSTALLATION 1. Install the hose (3). 2. Install the banjo bolt (1) at the caliper and tighten fitting bolt to 27 Nm (245 inch lbs.). 3. Install the mounting bolt (2) for the brake hose (3) at the axle. 4. Install the brake line located at the axle. 5. Lower the vehicle and remove the support. 6. Bleed the brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring > Page 5138 Brake Hose/Line: Service and Repair Front Brake Hose FRONT BRAKE HOSE REMOVAL 1. Raise and support vehicle. 2. Remove the tire and wheel assembly 3. Remove the brake hose (2) from the brake line located at the frame. 4. Remove the brake hose banjo bolt (3) at the caliper. 5. Remove the mounting bolt securing the brake hose (2) to the frame and remove the wheel speed sensor wire (4) from the brake hose (2). 6. Remove the hose. INSTALLATION 1. Install the hose (3). 2. Install the mounting bolt (1) for the brake hose (3) at the frame. 3. Install the brake hose banjo bolt at the caliper. 4. Reinstall the wheel speed sensor wire (2) to the brake hose. 5. Remove the support and lower the vehicle. 6. Bleed the brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring > Page 5139 Brake Hose/Line: Service and Repair Rear Brake Hose REAR BRAKE HOSE REMOVAL 1. Raise and support the vehicle. 2. Remove the brake line (3) from the hose (1) at the frame. 3. Remove the brake hose clip (2) at the top of the hose located at the frame. 4. Remove the vent hose (2). 5. Remove the two brake lines (3) at the bottom of the hose (1) located at the axle. 6. Remove the mounting bolt for the brake hose at the axle. 7. Remove the hose. INSTALLATION 1. Install the hose (1). 2. Install the mounting bolt for the brake hose (1) at the axle. 3. Install the two brake lines (3) at the bottom of the hose located at the axle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Flaring > Page 5140 4. Install the vent hose (2). 5. Install the brake hose clip (2) at the top of the hose (1) located at the frame. 6. Install the brake line (3) to the hose at the frame. 7. Lower the vehicle and remove the support. 8. Bleed the brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation HCU (HYDRAULIC CONTROL UNIT) DESCRIPTION The HCU (3) consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. OPERATION Accumulators in the valve body store extra fluid released to the system for ABS mode operation. The pump provides the fluid volume needed and is operated by a DC type motor. The motor is controlled by the ABM. The valves modulate brake pressure during antilock braking and are controlled by the ABM. The HCU provides three channel pressure control to the front and rear brakes. One channel controls the rear wheel brakes in tandem. The two remaining channels control the front wheel brakes individually. During antilock braking, the solenoid valves are opened and closed as needed. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. NOTE: The three modes mentioned below do occur but not necessarily in the order listed every time. During antilock braking, solenoid valve pressure modulation occurs in three stages, pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the ABM closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the ABM closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The ABM maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply the brakes. This cycle controls re-application of fluid apply pressure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control Unit (HCU) HCU (HYDRAULIC CONTROL UNIT) REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connectors. 4. Remove the brake lines from the HCU (3). 5. Remove HCU/ABM mounting bolts (1) and remove the HCU/ABM (3) from the battery tray (4). INSTALLATION NOTE: If the ABM (2) is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install HCU/ABM (3) on the mounts to the battery tray (4) and Tighten the bolts to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the HCU (3) and tighten to 19 Nm (170 inch lbs.). 3. Install the electrical harness connectors to the HCU/ABM (3) and push down on the release to secure the connectors. 4. Install the battery 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control Unit (HCU) > Page 5146 Hydraulic Control Assembly - Antilock Brakes: Service and Repair RWAL Valve VALVE-RWAL REMOVAL 1. Disconnect the battery cables from the battery. 2. Remove the battery. 3. Disconnect the electrical harness connector. 4. Remove the brake lines from the RWAL valve (1). 5. Remove RWAL valve mounting nuts (2) and remove the RWAL valve (1). INSTALLATION 1. Install RWAL valve (1) and Tighten the nuts (2) to 15 Nm (11 ft. lbs.). 2. Install the brake lines to the RWAL valve and tighten to 19 Nm (170 inch lbs.). 3. Install the electrical harness connector to the RWAL valve and secure the connector. 4. Install the battery. 5. Install the battery cables to the battery. 6. Bleed ABS brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Service and Repair Hydraulic System Junction Block: Service and Repair BRAKE JUNCTION BLOCK REMOVAL 1. Remove the brake lines (1) from the junction block (2). 2. Remove the junction block (2) mounting bolt and remove the junction block from the bracket. INSTALLATION 1. Position the junction block (2) on the bracket and install the mounting bolt. Tighten the mounting bolt to 23 Nm (210 inch lbs.). 2. Install the brake lines (1) into the junction block (2) and tighten to 19 - 23 Nm (170 - 200 inch lbs.). 3. Bleed the base brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation Brake Master Cylinder: Description and Operation MASTER CYLINDER DESCRIPTION A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits and has a switch for indicating low fluid levels. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 5153 Brake Master Cylinder: Testing and Inspection MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Fluid Reservoir Brake Master Cylinder: Service and Repair Master Cylinder Fluid Reservoir RESERVOIR-FLUID REMOVAL 1. Install the prop rod on the brake pedal to keep pressure on the brake system. 2. Remove the reservoir cap (1) and siphon fluid into a drain container. 3. Remove the electrical connector from the fluid level switch (3) in the reservoir (2). 4. Remove the reservoir mounting bolt (5). 5. Remove the reservoir (2) from the master cylinder (4) by pulling upwards. 6. Remove old grommets from cylinder body INSTALLATION CAUTION: Do not use any type of tool to install the grommets. Tools may cut, or tear the grommets creating a leak problem after installation. Install the grommets using finger pressure only. 1. Lubricate the new grommets (6) with clean brake fluid and Install new grommets in cylinder body. Use finger pressure to install and seat grommets (6). 2. Start the reservoir (2) in grommets (6). Then rock the reservoir back and forth while pressing downward to seat it into the grommets. 3. Install the mounting bolt (5) for the reservoir (2) to the master cylinder (4). 4. Reconnect the electrical connector to the fluid reservoir level switch (3). 5. Remove the prop rod from the vehicle. 6. Fill and bleed base brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Fluid Reservoir > Page 5156 Brake Master Cylinder: Service and Repair Master Cylinder Bleeding MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Fluid Reservoir > Page 5157 Brake Master Cylinder: Service and Repair Master Cylinder - All Except Hydroboost ALL EXCEPT HYDROBOOST REMOVAL 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Disconnect the electrical connector for the low fluid level. 4. Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage. 5. Remove the brake lines (3) from the master cylinder (4). 6. Remove the mounting nuts from the master cylinder (4). 7. Remove the master cylinder (4). NOTE: Gently ease the master cylinder & reservoir assembly away from the booster, During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod from its seat inside the booster. INSTALLATION NOTE: If master cylinder is replaced bleed cylinder before installation. NOTE: Make sure the output rod of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly check that there is a vacuum seal present at the shoulder of the master cylinder flange and it's neck. A square seal must be present to ensure vacuum integrity with the booster. 1. Gently install the master cylinder (9) on the booster mounting studs (4). NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Fluid Reservoir > Page 5158 2. Install new mounting nuts and tighten to 25 Nm (221 inch lbs.). 3. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Fluid Reservoir > Page 5159 Brake Master Cylinder: Service and Repair Master Cylinder - Hydroboost HYDROBOOST REMOVAL 1. Remove the brake lines from the master cylinder. 2. Disconnect the electrical connector for the low fluid level. 3. Remove the mounting nuts (4) from the master cylinder (3). 4. Remove the master cylinder (3). NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. INSTALLATION NOTE: If master cylinder is replaced bleed cylinder before installation. 1. Install the master cylinder (3) on the booster mounting studs. 2. Install new mounting nuts (4) and tighten to 25 Nm (221 inch lbs.). 3. Install the brake lines and tighten to 19 Nm (170 inch lbs.). 4. Reconnect the electrical connector for the low fluid level switch. 5. Fill and bleed the base brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair Parking Brake Backing Plate: Service and Repair PLATE-SUPPORT REMOVAL 1. Remove wheel and tire assembly 2. Remove the disc brake caliper. 3. Remove the caliper adapter. 4. Remove the rotor. 5. Remove the axle shaft. 6. Remove the park brake shoes. 7. Remove the parking brake cable from the brake lever. 8. Remove the bolts (2) attaching the support plate (1) to the axle and remove the support plate. INSTALLATION 1. Install support plate (1) on axle flange. Tighten attaching bolts (2) to 68 Nm (50 ft. lbs.) LD or 203 Nm (150 ft. lbs) HD. 2. Install parking brake cable in the brake lever. 3. Install the park brake shoes. 4. Install axle shaft. 5. Adjust brake shoes to drum with brake gauge. 6. Install the rotor. 7. Install the caliper adapter. 8. Install the caliper. 9. Install the wheel and tire assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable: Service and Repair Front FRONT PARKING BRAKE CABLE REMOVAL 1. Raise and support vehicle. 2. Lockout the parking brake cable (2). 3. Loosen adjusting nut to create slack in front cable. 4. Remove the front cable from the cable connector. 5. Compress cable end fitting at underbody bracket and remove the cable from the bracket. 6. Lower vehicle. 7. Push ball end of cable out of pedal clevis with small screwdriver. 8. Compress cable end fitting at the pedal bracket (1) and remove the cable (2). 9. Remove the left cowl trim and sill plate. 10. Pull up the carpet and remove the cable from the body clip. 11. Pull up on the cable and remove the cable with the body grommet. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5168 1. From inside the vehicle, insert the cable end fitting (2) into the hole in the pedal assembly (1). 2. Seat the cable retainer in the pedal assembly (1). 3. Engage the cable ball end in clevis on the pedal assembly. 4. Route the cable through the floor pan and install the body grommet. 5. Place the carpet down and install the left cowl trim and sill plate. 6. Raise and support the vehicle. 7. Route the cable through the underbody bracket and seat the cable end fitting in the bracket. 8. Connect the cable to the cable connector. 9. Perform the park brake adjustment procedure. 10. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5169 Parking Brake Cable: Service and Repair Rear CABLES REMOVAL REAR PARK BRAKE CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen cable adjuster nut. 4. Remove the rear park brake cable from the intermediate park brake cable. 5. Compress tabs on cable end fitting on the rear park brake cable to the frame mount bracket. Then pull the cable through the bracket. 6. Disengage the park brake cable (2) from behind the rotor assembly. 7. Compress cable tabs on each cable end fitting at the brake cable support plate. 8. Remove the cables from the brake cable support plates. RIGHT REAR CABLE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5170 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the right cable from the front cable. 5. Remove the right cable from the equalizer. 6. Remove the cable from the frame bracket. 7. Remove the cable from the axle bracket. 8. Remove the cable bracket from the shock bracket. 9. Remove the brake cable (4) from the brake lever (3). LEFT REAR CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (2). 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the left brake cable from the equalizer. 5. Remove the brake cable (4) from the frame bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5171 6. Remove the brake cable (4) from the brake lever. INSTALLATION REAR PARK BRAKE CABLE 1. Push each cable end (2) through the brake cable support plate hole until the cable end fitting tabs lock into place. NOTE: Pull on the cable to ensure it is locked into place. 2. Push the cable through the frame bracket. 3. Lock the left cable end fitting tabs into the frame bracket hole. 4. Install the rear cables into the tensioner rod behind the rear of the brake assembly 5. Install the cable to the intermediate cable connector. 6. Release and remove the lock out device. 7. Perform the park brake adjustment procedure. 8. Remove the supports and lower the vehicle. RIGHT REAR CABLE 1. Install the brake cable (2) to the brake lever (3). 2. Install the cable bracket to the shock bracket. 3. Install the cable to the axle bracket. 4. Install the cable to the frame bracket. 5. Install the right cable to the equalizer. 6. Install the right cable to the front cable. 7. Adjust the brake cable at the equalizer and using the adjuster nut. LEFT REAR CABLE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 5172 1. Install the brake cable (4) to the brake lever. 2. Install the brake cable to the frame bracket. 3. Install the left brake cable to the equalizer. 4. Adjust the brake cable at the equalizer and adjuster nut. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Pedal Parking Brake Pedal: Service and Repair Pedal PEDAL REMOVAL 1. Release the parking brake. 2. Raise the vehicle. 3. Loosen the cable tensioner nut at the equalizer to create slack in the front cable. 4. Lower the vehicle. 5. Remove the knee bolster. 6. Disconnect the brake lamp wire from the switch on the pedal assembly (2). 7. Roll the carpet back, loosen the front cable grommet from the floor pan and the cable retainer. 8. Disengage the release rod (1) from the arm on the pedal assembly (2). 9. Remove the bolts/nuts from the pedal assembly (2) and remove the assembly INSTALLATION 1. Position the replacement pedal assembly (1) on the dash and cowl. 2. Install the bolts/nuts (2) and tighten to 28 Nm (21 ft. lbs.). 3. Install the park brake release rod. 4. Connect the front cable to the arm on the pedal assembly (1). 5. Install the front cable grommet into the floor pan and the cable retainer, roll the carpet back. 6. Connect the wires to the brake lamp switch. 7. Install the knee bolster. 8. Raise the vehicle. 9. Adjust the parking brake cable tensioner. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Pedal > Page 5177 Parking Brake Pedal: Service and Repair Release Handle HANDLE-RELEASE REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the driver side outboard end of the instrument panel to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel. 3. Disengage the park brake release linkage rod end from the park brake mechanism. 4. Lift the park brake release handle to access and unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle. 5. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to disengage the park brake release linkage rod end from the lever on the back of the park brake release handle. 6. Lift the park brake release handle to access the handle mounting bracket. 7. Using a trim stick (4) or another suitable wide flatbladed tool, gently pry each of the park brake release handle (6) mounting bracket latch tabs (5) away from the retaining notches in the instrument panel receptacle. 8. With both of the park brake release handle mounting bracket latches released, slide the handle and bracket assembly down and out of the instrument panel receptacle. INSTALLATION 1. Position the park brake release handle to the instrument panel. 2. Slide the handle and bracket assembly up into the instrument panel receptacle until both of the park brake release handle (6) mounting bracket Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Pedal > Page 5178 latches are engaged with the notches in the instrument panel receptacle. 3. Lower the park brake release handle and reach under the driver side outboard end of the instrument panel to engage the park brake release linkage rod end with the lever on the back of the park brake release handle (6). 4. Lift the park brake release handle to access and snap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back of the park brake release handle over the linkage rod. 5. Reach under the driver side outboard end of the instrument panel to access and engage the park brake release linkage rod end to the park brake mechanism. 6. Snap the plastic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel over the linkage rod. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments ADJUSTMENTS PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. 3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from the axle shaft. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. 5. Using Brake Shoe Gauge, Special Tool C-3919 (1), or equivalent, accurately measure the inside diameter of the park brake drum portion (2) of the rotor. 6. Using a ruler (2) that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5182 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 (2) by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 (2) or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on the axle shaft. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter. 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.) LID, 197 Nm (145 ft. lbs.) HID SRW, 210 Nm (155 ft. lbs.) HID DRW. 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. WITH ADJUSTING TOOL Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. 1. Be sure parking brake lever is fully released. 2. Raise vehicle so rear wheels can be rotated freely. 3. Remove plug from each access hole in brake support plates. 4. Loosen parking brake cable adjustment nut until there is slack in front cable. 5. Insert adjusting tool (4) through support plate access hole (1) and engage tool in teeth of adjusting screw star wheel (2). 6. Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. 7. Push and hold adjuster lever away from star wheel with thin screwdriver (3). 8. Back off adjuster screw star wheel until brake drag is eliminated. 9. Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. 10. Install support plate access hole plugs. 11. Adjust parking brake cable and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5183 12. Depress park brake pedal and make sure park brakes hold the vehicle stationary. 13. Release park brake pedal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5184 Parking Brake Shoe: Service and Repair SHOES REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly 3. Remove the disc brake caliper. 4. Remove the disc brake rotor. 5. Lockout the parking brake cable (2). 6. Disengage the park brake cable (2) from behind the rotor assembly to allow easier disassembly of the park brake shoes. 7. Remove the axle shaft (1). 8. Disassemble the rear park brake shoes (4). CLEANING - REAR DRUM IN HAT BRAKE Clean the individual brake components, including the support plate exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5185 INSPECTION - REAR DRUM IN HAT BRAKE As a general rule, riveted brake shoes (2) should be replaced when worn to within 0.78 mm (1/32 inch) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 inch). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes (2) exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly (5). Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs (3) and retainer components (4) if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate (1), replace the support plate if any of the pads are worn or rusted through. Also replace the plate (1) if it is bent or distorted. INSTALLATION NOTE: On a new vehicle or after parking brake lining replacement, it is recommended that the parking brake system be conditioned prior to use. This is done by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal. 1. Reassemble the rear park brake shoes (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 5186 2. Install the axle shaft (1). 3. Install the park brake cable to the lever behind the support plate. 4. Unlock the park brake cable. 5. Install the disc brake rotor. 6. Install the disc brake caliper. 7. Adjust the rear brake shoes. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments TENSIONER-CABLE ADJUSTMENTS CABLE TENSIONER NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise the vehicle. 2. Back off the cable tensioner adjusting nut (5) to create slack in the cables. 3. Remove the rear wheel/tire assemblies. Then remove the brake rotors. 4. Verify the brakes are in good condition and operating properly 5. Verify the park brake cables operate freely and are not binding, or seized. 6. Check the rear brake shoe adjustment with standard brake gauge. 7. Install the rotors and verify that the rotors rotate freely without drag. 8. Install the wheel/tire assemblies. 9. Lower the vehicle enough for access to the park brake foot pedal. Then fully apply the park brakes. NOTE: Leave park brakes applied until adjustment is complete. 10. Raise the vehicle again. 11. Mark the tensioner rod 6.35 mm (1/4 inch) from edge of the tensioner (2). 12. Tighten the adjusting nut (5) on the tensioner rod until the mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower the vehicle until the rear wheels are 15 - 20 cm (6 - 8 inch) off the shop floor. 14. Release the park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation A brake indicator is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of a stencil-like cutout of the word BRAKE and the International Control and Display Symbol icon for Brake Failure in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text and icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. The CAB can also send brake lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to testing. The park brake switch input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the CAN data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 5193 Parking Brake Warning Lamp: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired park brake switch input to the EMIC may be diagnosed and tested using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus, or the electronic message inputs also used by the EMIC to provide brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAB, the CAN data bus, and the electronic message inputs for the brake indicator operation requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5197 Switch - Parking Brake Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5198 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Refer to appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5199 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an inoperative park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5200 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection Hydraulic Brake Booster: Testing and Inspection HYDRAULIC BOOSTER The hydraulic booster uses hydraulic pressure from the power steering pump. Before diagnosing a booster problem, first verify the power steering pump is operating properly Perform the following checks. ^ Check the power steering fluid level. ^ Check the brake fluid level. ^ Check all power steering hoses and lines for leaks and restrictions. ^ Check power steering pump pressure. NOISES The hydraulic booster unit will produce certain characteristic booster noises. The noises may occur when the brake pedal is used in a manner not associated with normal braking or driving habits. HISSING A hissing noise may be noticed when above normal brake pedal pressure is applied, 40 lbs. or above. The noise will be more noticeable if the vehicle is not moving. The noise will increase with the brake pedal pressure and an increase of system operating temperature. CLUNK-CHATTER-CLICKING A clunk-chatter-clicking may be noticed when the brake pedal is released quickly, after above normal brake pedal pressure is applied 50-100 lbs. BOOSTER FUNCTION TEST With the engine off depress the brake pedal several times to discharge the accumulator. Then depress the brake pedal using 40 lbs. of force and start the engine. The brake pedal should fall and then push back against your foot. This indicates the booster is operating properly. ACCUMULATOR LEAKDOWN 1. Start the engine, apply the brakes and turn the steering wheel from lock to lock. This will ensure the accumulator is charged. Turn off the engine and let the vehicle sit for one hour. After one hour there should be at least two power assisted brake application with the engine off. If the system does not retain a charge the booster must be replaced. 2. With the engine off depress the brake pedal several times to discharge the accumulator. Grasp the accumulator and see if it wobbles or turns. If it does the accumulator has lost a gas charge and the booster must be replaced. SEAL LEAKAGE If the booster leaks from any of the seals the booster assembly must be replaced. ^ INPUT ROD SEAL (3): Fluid leakage from rear end of the booster. ^ PISTON SEAL (6): Fluid leakage from vent at front of booster. ^ HOUSING SEAL (4): Fluid leakage between housing and housing cover. ^ SPOOL VALVE SEAL (7): Fluid leakage near spool plug. ^ RETURN PORT FITTING SEAL (8): Fluid leakage from port fitting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Testing and Inspection > Page 5205 HYDRAULIC BOOSTER DIAGNOSIS CHART Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Removal and Installation Hydraulic Brake Booster: Service and Repair Removal and Installation BOOSTER-HYDRO-BOOST BRAKE REMOVAL NOTE: If the booster is being replaced because the power steering fluid is contaminated, flush the power steering system before replacing the booster. 1. With engine off depress the brake pedal 5 times to discharge the accumulator. 2. Remove brake lines from master cylinder. 3. Remove mounting nuts from the master cylinder. 4. Remove the bracket from the hydraulic booster lines and master cylinder mounting studs. 5. Remove the master cylinder (3). 6. Remove the return hose (4) and the two pressure lines (1&5) from the hydraulic booster (2). 7. Remove the booster push rod clip, washer and rod remove from the brake pedal. 8. Remove the mounting nuts from the hydraulic booster and remove the booster. INSTALLATION 1. Install the hydraulic booster (2) and tighten the mounting nuts to 28 Nm (21 ft. lbs.). 2. Install the booster push rod, washer and clip onto the brake pedal. 3. Install the master cylinder (3) on the mounting studs. and tighten the mounting nuts to 23 Nm (17 ft. lbs.). 4. Install the brake lines to the master cylinder and tighten to 19 Nm (170 inch lbs.). 5. Install the hydraulic booster line bracket onto the master cylinder mounting studs. 6. Install the master cylinder mounting nuts and tighten to 23 Nm (17 ft. lbs.). 7. Install the hydraulic booster pressure lines (1&5) to the bracket and booster. 8. Tighten the pressure lines to 41 Nm (30 ft. lbs.). NOTE: Inspect O-rings on the pressure line fittings to insure they are in good condition before installation. Replace O-rings if necessary. 9. Install the return hose (4) to the booster. 10. Bleed base brake system. 11. Fill the power steering pump with fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Removal and Installation > Page 5208 CAUTION: MOPAR (MS-9602) ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. 12. Bleed the hydraulic booster. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Hydraulic Brake Booster > Component Information > Service and Repair > Removal and Installation > Page 5209 Hydraulic Brake Booster: Service and Repair Bleeding BLEEDING The hydraulic booster is generally self-bleeding, this procedure will normally bleed the air from the booster. Normal driving and operation of the unit will remove any remaining trapped air. 1. Fill power steering pump reservoir. 2. Disconnect fuel shutdown relay and crank the engine for several seconds. 3. Check fluid level and add if necessary. 4. Connect fuel shutdown relay and start the engine. 5. Turn the steering wheel slowly from lock to lock twice. 6. Stop the engine and discharge the accumulator by depressing the brake pedal 5 times. 7. Start the engine and turn the steering wheel slowly from lock to lock twice. 8. Turn off the engine and check fluid level and add if necessary. NOTE: If fluid foaming occurs, wait for foam to dissipate and repeat steps 7 and 8. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation BOOSTER-POWER BRAKE DESCRIPTION All models use a tandem diaphragm, power brake booster (3). NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. OPERATION The booster unit consists of a single housing divided into two by a tandem diaphragm (3). The outer edge of the diaphragm is secured to the housing. A spacer block (2) is located in between the cowl and the booster housing. The booster push rod (1), connects the booster to the brake pedal and master cylinder (4), is attached to the center of the diaphragm. A check valve (5) is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5213 Vacuum Brake Booster: Testing and Inspection MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5214 Vacuum Brake Booster: Service and Repair BOOSTER-POWER BRAKE REMOVAL 1. Remove master cylinder. 2. Disconnect vacuum line at booster. 3. Remove clip securing booster push rod to brake pedal. 4. Remove the nuts (1) from the booster mounting studs. 5. Remove the booster (2) and gasket from front cowl panel. INSTALLATION 1. Guide the booster (2) studs into the cowl panel holes and seat the booster on the panel. 2. Install and tighten new booster attaching nuts (1) to 28 Nm (250 inch lbs.). 3. Install the booster push rod on brake pedal and install clip. 4. Install the booster check valve if removed and connect the vacuum hose to the check valve. 5. Install the master cylinder. 6. Fill and bleed the brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement Technical Service Bulletin # F05 Date: 060701 Recall - ABS Control Module Replacement Revised July 2006 Dealer Service Instructions for: Safety Recall F05 Antilock Brake System Control Module Please remove and discard from your files all previous copies of Safety Recall F05 (dated June 2006). This revision has additional parts information to clarify the ABS Control Module application for Dodge Ram Mega Cab models. Models 2006 (DR) Dodge Ram Pickup Truck (1500 Series) 2006 (DH) Dodge Ram Pickup Truck (1500 Mega Cab & 2500 Series) 2006 (D1) Dodge Ram Pickup Truck (3500 Series) 2006 (ND) Dodge Dakota Pickup Truck NOTE: This recall applies only to the above vehicles equipped with a Four-Wheel Antilock Brake System (sales code BGK or BRT) built from September 12, 2005 through December 11, 2005 (MDH 091221 through 121114). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Antilock Brake System (ABS) control module on about 37,900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be replaced and initialized with the StarSCAN tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5224 Parts Information The ABS module part number for the vehicle to be serviced may also be determined as follows: > From the DealerCONNECT "Service" tab, in the "Write Up" box under "Vehicle Information Plus" select "Single VIN Inquiry." Enter the VIN and odometer reading and click the "View" button. Select the Recall Tab and the recall part number will be displayed. > From the DealerCONNECT "Service" tab, select "Global Recall System." Click on the recall number, select "List by VIN" from drop down menu, and click the "Submit" button. A list of incomplete involved vehicles for your dealer will be generated. NOTE: If F05 is not listed, there are no involved vehicles assigned to your dealer code. Special Tools Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5225 The existing special tools shown will be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5226 schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: The StarSCAN must be used to initialize the new ABS control module after installation. 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Clean the ABS control module to prevent dirt from falling into the hydraulic control unit when the ABS control module is removed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5227 NOTE: The ABS control module is located next to the battery on DR/DH and D1 models (Dodge Ram Truck) (Figure 1). The ABS control module is located under the Power Distribution Center on ND models (Dodge Dakota) (Figure 2). 3. Pull up on the ABS control module harness connector lock and disconnect the wiring from the ABS control module (Figure 1). 4. Using a T-20 Torx driver, remove and discard the ABS control module mounting screws (Figure 3). 5. Remove and discard the ABS control module from the Hydraulic Control Unit (HCU). 6. Install the new ABS control module onto the HCU. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5228 7. Install the new ABS control module mounting screws included in the kit (Figure 4). Tighten the screws to 35 in. lbs. (4 N.m). 8. Connect the wiring harness to the ABS control module and push down on the connector lock to secure the connector. 9. Connect the negative battery cable(s) to the negative battery terminal(s). 10. Connect the StarSCAN to the data link connector located under the steering column. 11. Place the ignition key in the "RUN" position (engine not running). 12. Push the power button on the StarSCAN and wait for the scan tool to "power up." 13. From the Home Screen, select "ECU¡ VIEW". 14. Select "ABS Anti-lock Brakes / Electronic Stability". 15. Select "Misc. Functions" on the screen. 16. Select "Initialize ECU" and then press the "START" button. 17. Press the "NEXT" button. 18. Follow the scan tool screen prompts to complete the ECU initializing process. 19. Select the "BACK" button twice. 20. After completing ABS control module reprogramming clear all fault codes using the following procedure: a. Return to the "Main Menu" (Home Page) and select "System View". b. Select "All DTC's" c. Select "Clear All Stored DTC's" and then follow the screen prompts. 21. Remove the StarSCAN from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5229 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Recalls for Electronic Brake Control Module: > NHTSA06V038000 > Feb > 06 > Recall 06V038000: ABS ECU Replacement Electronic Brake Control Module: Recalls Recall 06V038000: ABS ECU Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2006 Dodge/Ram 2006 Mitsubishi/Raider 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V038000 MFG'S REPORT DATE: February 07, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 39274 SUMMARY: On certain pickup trucks equipped with four-wheel Antilock Brake Systems (ABS), The ABS Electronic Control Unit (ECU) may cause a loss of front to rear brake balance, and the rear brakes could lock up prematurely during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the ABS ECU. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F05. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement Technical Service Bulletin # F05 Date: 060701 Recall - ABS Control Module Replacement Revised July 2006 Dealer Service Instructions for: Safety Recall F05 Antilock Brake System Control Module Please remove and discard from your files all previous copies of Safety Recall F05 (dated June 2006). This revision has additional parts information to clarify the ABS Control Module application for Dodge Ram Mega Cab models. Models 2006 (DR) Dodge Ram Pickup Truck (1500 Series) 2006 (DH) Dodge Ram Pickup Truck (1500 Mega Cab & 2500 Series) 2006 (D1) Dodge Ram Pickup Truck (3500 Series) 2006 (ND) Dodge Dakota Pickup Truck NOTE: This recall applies only to the above vehicles equipped with a Four-Wheel Antilock Brake System (sales code BGK or BRT) built from September 12, 2005 through December 11, 2005 (MDH 091221 through 121114). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The Antilock Brake System (ABS) control module on about 37,900 of the above vehicles may cause the rear brakes to lock up during certain braking conditions. This could result in a loss of vehicle control and cause a crash without warning. Repair The ABS control module must be replaced and initialized with the StarSCAN tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5239 Parts Information The ABS module part number for the vehicle to be serviced may also be determined as follows: > From the DealerCONNECT "Service" tab, in the "Write Up" box under "Vehicle Information Plus" select "Single VIN Inquiry." Enter the VIN and odometer reading and click the "View" button. Select the Recall Tab and the recall part number will be displayed. > From the DealerCONNECT "Service" tab, select "Global Recall System." Click on the recall number, select "List by VIN" from drop down menu, and click the "Submit" button. A list of incomplete involved vehicles for your dealer will be generated. NOTE: If F05 is not listed, there are no involved vehicles assigned to your dealer code. Special Tools Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5240 The existing special tools shown will be required to perform this repair. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5241 schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: The StarSCAN must be used to initialize the new ABS control module after installation. 1. Disconnect the negative battery cable(s). NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Clean the ABS control module to prevent dirt from falling into the hydraulic control unit when the ABS control module is removed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5242 NOTE: The ABS control module is located next to the battery on DR/DH and D1 models (Dodge Ram Truck) (Figure 1). The ABS control module is located under the Power Distribution Center on ND models (Dodge Dakota) (Figure 2). 3. Pull up on the ABS control module harness connector lock and disconnect the wiring from the ABS control module (Figure 1). 4. Using a T-20 Torx driver, remove and discard the ABS control module mounting screws (Figure 3). 5. Remove and discard the ABS control module from the Hydraulic Control Unit (HCU). 6. Install the new ABS control module onto the HCU. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5243 7. Install the new ABS control module mounting screws included in the kit (Figure 4). Tighten the screws to 35 in. lbs. (4 N.m). 8. Connect the wiring harness to the ABS control module and push down on the connector lock to secure the connector. 9. Connect the negative battery cable(s) to the negative battery terminal(s). 10. Connect the StarSCAN to the data link connector located under the steering column. 11. Place the ignition key in the "RUN" position (engine not running). 12. Push the power button on the StarSCAN and wait for the scan tool to "power up." 13. From the Home Screen, select "ECU¡ VIEW". 14. Select "ABS Anti-lock Brakes / Electronic Stability". 15. Select "Misc. Functions" on the screen. 16. Select "Initialize ECU" and then press the "START" button. 17. Press the "NEXT" button. 18. Follow the scan tool screen prompts to complete the ECU initializing process. 19. Select the "BACK" button twice. 20. After completing ABS control module reprogramming clear all fault codes using the following procedure: a. Return to the "Main Menu" (Home Page) and select "System View". b. Select "All DTC's" c. Select "Clear All Stored DTC's" and then follow the screen prompts. 21. Remove the StarSCAN from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > F05 > Jul > 06 > Recall - ABS Control Module Replacement > Page 5244 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Brake Control Module: > NHTSA06V038000 > Feb > 06 > Recall 06V038000: ABS ECU Replacement Electronic Brake Control Module: All Technical Service Bulletins Recall 06V038000: ABS ECU Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/Dakota 2006 Dodge/Ram 2006 Mitsubishi/Raider 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V038000 MFG'S REPORT DATE: February 07, 2006 COMPONENT: Service Brakes, Hydraulic: Antilock: Control Unit/Module POTENTIAL NUMBER OF UNITS AFFECTED: 39274 SUMMARY: On certain pickup trucks equipped with four-wheel Antilock Brake Systems (ABS), The ABS Electronic Control Unit (ECU) may cause a loss of front to rear brake balance, and the rear brakes could lock up prematurely during certain braking conditions. CONSEQUENCE: This could result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the ABS ECU. The manufacturer has not yet provided an owner notification schedule for this campaign. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F05. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5249 Electronic Brake Control Module: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5250 Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5251 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5252 Electronic Brake Control Module: Diagrams Module - Anti-lock Brakes (RWAL) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5253 Module - Anti-lock Brakes (AWAL) Module - Brake Provision Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5254 Electronic Brake Control Module: Description and Operation The Antilock Brake Module (ABM) (2) is mounted to the Hydraulic Control Unit (HCU) (3) and operates the ABS system. The ABM voltage source is through the ignition switch in the RUN position. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Technical Service Bulletins > Page 5255 Electronic Brake Control Module: Service and Repair REMOVAL 1. Remove the negative battery cable from the battery. 2. Pull up on the ABM harness connector release and remove connector. 3. Remove the ABM mounting bolts. 4. Remove the pump connector from the ABM. 5. Remove the ABM from the HCU. INSTALLATION NOTE: If the ABM is being replaced with a new ABM is must be reprogrammed with the use of a scan tool. 1. Install ABM to the HCU. 2. Install the pump connector to the ABM. 3. Install mounting bolts. Tighten to 2 N.m (16 in. lbs.). 4. Install the wiring harness connector to the ABM and push down on the release to secure the connector. 5. Install negative battery cable to the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5260 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5261 Sensor - Brake Fluid Level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5265 Switch - Parking Brake Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5266 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Refer to appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5267 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an inoperative park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5268 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations Wheel Speed Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5272 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5273 Rear Chassis Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5274 Wheel Speed Sensor: Diagrams Sensor-Wheel Speed - ABS - Left Front Sensor-Wheel Speed - ABS - Rear Sensor-Wheel Speed - ABS - Right Front Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 5275 Wheel Speed Sensor: Description and Operation SENSOR- WHEEL SPEED-ABS-FRONT DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle differential housing. OPERATION The Wheel Speed Sensor consists of a magnet (1) surrounded by windings from a single strand of wire (5). The sensor sends a small AC signal to the ABM. This signal is generated by magnetic induction. The magnetic induction is created when a toothed sensor ring (exciter ring or tone wheel) (4) passes the stationary magnetic WSS. When the ring gear is rotated, the exciter ring (4) passes the tip of the WSS. As the exciter ring tooth approaches the tip of the WSS, the magnetic lines of force expand, causing the magnetic field to cut across the sensor's windings (5). This, in turn causes current to flow through the WSS circuit in one direction. When the exciter ring tooth moves away from the sensor tip, the magnetic lines of force collapse cutting the winding in the opposite direction. This causes the current to flow in the opposite direction. Every time a tooth of the exciter ring passes the tip of the WSS, an AC signal is generated current. Each AC signal (positive to negative signal or squarewave) is interpreted by the ABM. It then compares the frequency of the sinewave to a time value to calculate vehicle speed. The ABM continues to monitor the frequency to determine a deceleration rate that would indicate a possible wheel-locking tendency. The signal strength of any magnetic induction sensor is directly affected by: ^ Magnetic field strength; the stronger the magnetic field, the stronger the signal. ^ Number of windings in the sensor; more windings provide a stronger signal. ^ Exciter ring speed; the faster the exciter ring/tone wheel rotates, the stronger the signal will be. ^ Distance (3) air gap between the exciter ring teeth and WSS; the closer the WSS is to the exciter ring/tone wheel, the stronger the signal will be. The WSS is not adjustable. A clearance specification has been established for manufacturing tolerances. If the clearance is not within these specifications, then either the WSS or other components may be damaged. The clearance between the WSS and the exciter ring is 0.005 0.050 in. The assembly plant performs a Rolls Test on every vehicle that leaves the assembly plant. One of the test performed is a test of the WSS. To properly test the sensor, the assembly plant connects test equipment to the Data Link Connector (DLC). This connector is located to the right of the steering column and attached to the lower portion of the instrument panel. The rolls test terminal is spliced to the WSS circuit. The vehicle is then driven on a set of rollers and the WSS output is monitored for proper operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear Wheel Speed Sensor: Testing and Inspection Rear REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The RWAL brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The CAB monitors the system inputs and outputs circuits to verify the system is operating properly If the CAB senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool is used to diagnose the RWAL system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Testing and Inspection > Rear > Page 5278 Wheel Speed Sensor: Testing and Inspection Tone Wheel-Rear WHEEL-TONE REAR WHEEL SPEED SENSOR Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking. The Antilock brake system performs several self-tests every time the ignition switch is turned on and the vehicle is driven. The ABM monitors the system inputs and outputs circuits to verify the system is operating properly. If the ABM senses a malfunction in the system it will set a DTC into memory and trigger the warning lamp. NOTE: A scan tool must be used to diagnose the Antilock Brake system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front SENSOR- WHEEL SPEED-ABS-FRONT REMOVAL 1. Remove the front rotor. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 inch lbs.). 4. Install the front rotor and brake caliper assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5281 Wheel Speed Sensor: Service and Repair Rear SENSOR-WHEEL SPEED-ABS-REAR REMOVAL 1. Raise the vehicle on a hoist. 2. Remove the brake line mounting nut and remove the brake line from the sensor stud. 3. Remove the mounting stud (2) from the sensor and shield. 4. Remove the sensor (1) and shield from the differential housing (3). 5. Disconnect the sensor wire harness and remove the sensor (1). INSTALLATION 1. Connect the harness to the sensor. Be sure the seal is securely in place between the sensor and the wiring connector. 2. Install the O-ring on the sensor (if removed). 3. Insert the sensor (1) in the differential housing (3). 4. Install the sensor shield. 5. Install the sensor mounting stud (2) and tighten to 24 Nm (200 inch lbs.). 6. Install the brake line on the sensor stud (2)and install the nut. 7. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5287 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5288 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 5289 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 5297 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5302 Relay - Starter Motor (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5303 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5304 Starter Relay: Testing and Inspection The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12 V battery to terminals 85 an 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch, Transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 5305 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover (2) from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation Battery Cable: Description and Operation The battery cables (1) and (3) are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire and then solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires (1) have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires (3) have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or inoperative they must be replaced. Both the battery positive and negative cables are available for service replacement. Refer to the appropriate wiring information for the location of the proper battery cable wire harness diagrams. The wiring information also includes proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires provide secure and reliable connection of the battery cables to the vehicle electrical system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5310 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST WARNING: MODELS EQUIPPED WITH A DIESEL ENGINE HAVE AN AUTOMATIC SHUTDOWN (ASD) RELAY LOCATED IN THE POWER DISTRIBUTION CENTER (PDC). REMOVAL OF THE ASD RELAY MAY NOT PREVENT THE DIESEL ENGINE FROM STARTING. BE CERTAIN TO DISCONNECT THE FUEL SHUTDOWN SOLENOID WIRE HARNESS CONNECTOR TO PREVENT THE ENGINE FROM STARTING. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and tested. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent a gasoline engine from starting, remove the Automatic Shutdown (ASD) relay. The ASD relay is located in the Integrated Power Module (IPM), in the engine compartment. See the fuse and relay layout label on the underside of the IPM cover for ASD relay identification and location. 1. Connect the positive lead of the voltmeter (1) to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. NOTE: If the vehicle is equipped with two 12 v batteries, step #1 must be performed twice, once for each battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5311 2. Connect the positive lead of the voltmeter (1) to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. NOTE: If the vehicle is equipped with two 12 v batteries, step #2 must be performed twice, once for each battery. 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid (3) B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. NOTE: If the vehicle is equipped with two 12 v batteries, step #3 must be performed twice, once for each battery. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground on the engine block (3). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 5312 NOTE: If the vehicle is equipped with two 12 v batteries, step #4 must be performed twice, once for each battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative Battery Cable: Service and Repair Negative REMOVAL 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamp (3). 3. Remove the bolt (4) securing the negative cable to the left front fender. 4. One at a time, trace the battery cable retaining pushpins (3), fasteners and routing clips until the cable is free from the vehicle. 5. Remove the bolt (4) securing the negative cable to the engine. 6. Remove the bolt (6) securing the negative cable to the left frame rail. 7. Remove the battery negative cable from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5315 1. Position the battery negative cable (5) in the vehicle. 2. One at a time, install the battery cable retaining pushpins (3), fasteners and routing clips until the cable is secure in the vehicle. 3. Install the bolt (6) securing the negative cable (1) to the left frame rail. 4. Install the bolt (4) securing the negative cable (5) to the engine. 5. Install the bolt (4) securing the negative cable (3) to the left front fender. 6. Connect the battery negative cable terminal clamp (3). 7. Check the vehicle for normal operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5316 Battery Cable: Service and Repair Positive REMOVAL 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable terminal clamp (3). 3. Disconnect the battery positive cable terminal clamp (1). 4. Remove the nut (9) securing the cable to the Integrated Power Module (IPM) (5). 5. Disconnect the wire harness connector (6) at the IPM. 6. Disconnect the wire harness connector (7) pushpin from the IPM housing. 7. Disconnect the battery cable retaining pushpin (8) securing the cable to the battery tray. 8. Raise the vehicle on a hoist. 9. Disconnect the battery cable retaining pushpins (1) securing the cable to the left frame rail. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5317 10. Remove the nut (5) securing the cable to the starter solenoid (6). 11. Lower the vehicle. 12. Lift the terminal cap (4) and remove the nut (3) securing the cable (1) to the alternator (2). 13. Disconnect any remaining pushpins securing the cable to the vehicle. 14. Remove the battery positive cable from the vehicle. INSTALLATION 1. Position the battery positive cable (1) in the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5318 2. Install the nut (3) securing the cable (1) to the alternator (2). 3. Secure the terminal cap (4) to the alternator stud. 4. Install the cable (1) pushpin into the bracket to the left of the alternator. 5. Raise the vehicle on a hoist. 6. Install the nut (5) securing the cable to the starter solenoid (6). 7. Connect the battery cable retaining pushpins (1) securing the cable to the left frame rail. 8. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Negative > Page 5319 9. Install the battery cable retaining pushpin (8) securing the cable to the battery tray 10. Install the wire harness connector (7) pushpin into the Integrated Power Module (IPM) (5) housing. 11. Connect the wire harness connector (6) at the IPM. 12. Install the nut (9) securing the cable to the IPM. 13. Connect the battery positive cable terminal clamp (1). 14. Connect the battery negative cable terminal clamp (3). 15. Check the vehicle for normal operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations Battery Temperature Sensor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5323 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5324 Battery Temperature Sensor: Description and Operation The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery The BTS is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM (ECM Diesel) to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. The PCM sends 5 volts to the sensor and is grounded through the sensor return line. As temperature increases, resistance in the sensor decreases and the detection voltage at the PCM increases. The BTS is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled, depending upon BTS input (for example, disable purge and enable Leak Detection Pump (LDP) and 02 sensor heater tests). Most OBD II monitors are disabled below 20° F. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Locations > Page 5325 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Remove battery. 2. Pry sensor (1) straight up from battery tray mounting hole to gain access to electrical connector (3). 3. Disconnect sensor from engine wire harness electrical connector. INSTALLATION NOTE: The battery temperature sensor (1) is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray (4). 1. Pull electrical connector (3) up through mounting hole in top of battery tray. 2. Connect sensor. 3. Snap sensor into battery tray. 4. Install battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL CAUTION: Never operate a vehicle without a battery hold down device properly installed. Damage to the vehicle, components and battery could result. 1. Verify that the ignition switch and all accessories are OFF. 2. Disconnect and isolate the battery negative cable. 3. Remove the bolt (6) from the battery hold down bracket (5) and remove the bracket from the vehicle. INSTALLATION 1. Clean and inspect the battery hold down bracket (5) and bolt (6). 2. Position the battery hold down bracket in the battery tray. CAUTION: Be certain that the hold down bracket is properly positioned in the battery tray before tightening the hold down bolt or damage to the battery and tray may result. 3. Install and tighten the battery hold down retaining bolt. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5330 Battery Tray: Service and Repair Battery Tray Left Side REMOVAL 1. Remove the battery (3) from the battery tray. 2. Remove the Integrated Power Module (IPM) (5). 3. Disconnect the wire harness retainers from the battery tray assembly. 4. Disconnect the purge solenoid (6) from its mounting bracket. 5. Remove the anti-lock brake controller (if equipped) retaining bolts and support the brake controller with mechanics wire. It is not necessary to completely remove the anti-lock brake control unit. 6. Remove the left front wheelhouse splash shield. 7. Mark the location of the cruise servo (3) (if equipped) and remove the retaining screws. Position the servo out of the way. 8. Remove the battery temperature sensor from the battery tray. 9. Disconnect the left front fender ground wire. 10. Remove the remaining battery tray retaining bolts (2). 11. Remove the battery tray from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5331 INSTALLATION 1. Position the battery tray assembly (1) and install the retaining bolts (2). 2. Connect the left front fender ground wire. 3. Install the battery temperature sensor in the battery tray. 4. Install the cruise servo (3) (if equipped) and retaining screws. 5. Install the left front wheelhouse splash shield. 6. Install the anti-lock brake controller (if equipped). 7. Install the purge solenoid (6) on its mounting bracket. 8. Connect the wire harness retainers on the battery tray assembly 9. Install the Integrated Power Module (IPM) (5). 10. Install the battery (3). Right Side REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 5332 1. Remove the battery from the battery tray. 2. Remove the right front wheelhouse splash shield. 3. Disconnect the right front fender ground wire. 4. Remove fasteners from grid heater relay bracket. 5. Remove air box. 6. Remove the remaining battery tray retaining bolts. 7. Remove the battery tray from the vehicle. INSTALLATION 1. Position the battery tray assembly and install the retaining bolts. 2. Connect the right front fender ground wire. 3. Install the air box. 4. Install the grid heater relay bracket. 5. Install the right front wheelhouse splash shield. 6. Install the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5338 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5339 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5340 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5341 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5342 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5343 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5344 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5345 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5346 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5347 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5348 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5349 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5350 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5351 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5352 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5353 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5354 Alternator: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5355 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5356 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5357 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5358 Alternator: Connector Views Generator (Except SRT) Generator (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5359 Alternator: Description and Operation The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any reason, the entire assembly must be replaced. As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor. The stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal. Although the generators appear the same externally, different generators with different output ratings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Generator Ratings in the Specifications at the back for amperage ratings and part numbers. Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defective drive pulley; incorrect, worn, damaged or misadjusted fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5360 Alternator: Service and Repair REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. 1. Disconnect negative battery cable at battery. 2. Remove generator drive belt. Refer to Cooling System for procedure. 3. Unsnap plastic insulator cap from B+ output terminal. 4. Remove B+ terminal mounting nut at rear of generator. Disconnect terminal from generator. 5. Disconnect field wire connector at rear of generator by pushing on connector tab. 6. Remove generator support bracket nuts (3) and bolt (4) and remove support bracket. 7. Remove 2 generator mounting bolts (1) and (3). 8. Remove generator from vehicle. INSTALLATION 1. Position generator to engine and install 2 mounting bolts. 2. Tighten bolts. Refer to Torque Specifications. 3. Position support bracket to front of generator and install bolt and nuts. Tighten bolt/nuts. Refer to Torque Specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5361 4. Snap field wire connector into rear of generator. 5. Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifications. CAUTION: - Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. - When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if the belt is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in Cooling System. 6. Install generator drive belt. 7. Install negative battery cable to battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the PCM (Powertrain Control Module) (within the ECM for diesel engines). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of direct current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature. It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Testing and Inspection Clutch Switch: Testing and Inspection CLUTCH PEDAL POSITION SWITCH 1. Disconnect switch 2-wire connector (2) attached to pedal support bracket (1), under instrument panel to left of clutch pedal. 2. Check switch continuity with an ohmmeter while operating clutch pedal. - Pedal Depressed - Continuity - Pedal Released - No Continuity 3. If continuity is not present or always present, replace clutch master cylinder. Switch is not serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair Ignition Lock: Service and Repair KEY CYLINDER REMOVAL The ignition key must be in the key cylinder (1) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at the underside of the key cylinder assembly a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key must be in the key cylinder (3) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (3) with the ignition switch (1). 2. Push the key cylinder (3) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation IGNITION SWITCH DESCRIPTION The ignition switch (5) is located on the steering column (4). It is used as the main on/off switching device for most electrical components. The mechanical key cylinder is used to engage/disengage the electrical ignition switch. OPERATION Vehicles equipped with an automatic transmission and a steering column mounted shifter: an interlock device is located within the shift cable. This interlock device is used to lock the transmission shifter in the PARK position when the key cylinder is in any position and the brake pedal is not depressed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 5376 Ignition Switch Lock Cylinder: Service and Repair KEY CYLINDER REMOVAL The ignition key (1) must be in the key cylinder (2) for cylinder removal. 1. Disconnect negative cable from battery. 2. Remove upper and lower covers (shrouds) from steering column. 3. Place shifter in PARK position. 4. A retaining pin is located at side of key cylinder assembly (2). a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder (1) from ignition switch. INSTALLATION The ignition key (1) must be in the key cylinder (2) for cylinder installation. 1. Install the key cylinder into the housing using care to align the end of the key cylinder (2) with the ignition switch. 2. Push the key cylinder (2) in until it clicks. 3. Replace the upper and lower shrouds. 4. Reconnect the battery. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams Starter Motor: Diagrams Starter (NGC) Starter - Eyelet (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5380 Starter Motor: Testing and Inspection Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5381 Starter Motor: Service and Repair REMOVAL 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. 3. NOTE: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt. 4. Remove 2 mounting bolts. 5. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire harness. 6. Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness. 7. Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud. 8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle. 9. Remove starter motor. INSTALLATION 1. Connect solenoid wire to starter motor (snaps on). 2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications. Do not allow starter motor to hang from wire harness. 3. Position starter motor to engine. 4. If equipped with automatic transmission, slide cooler tube bracket into position. 5. Install and tighten both mounting bolts. Refer to Torque Specifications. 6. Lower vehicle. 7. Connect negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5385 Relay - Starter Motor (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5386 Starter Relay: Description and Operation The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See PDC cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5387 Starter Relay: Testing and Inspection The starter relay is located in Power Distribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to Wiring Diagrams. 1. Remove starter relay from PDC 2. A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay. 3. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay. 4. Connect 12 V battery to terminals 85 an 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that follows. If not OK, replace faulty relay. RELAY CIRCUIT TEST 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open circuit to fuse in PDC as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required. 4. The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gearshift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay terminal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch, Transmission. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 5388 Starter Relay: Service and Repair REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover (2) from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Testing and Inspection Starter Solenoid: Testing and Inspection This test can only be performed with starter motor removed from vehicle. 1. Remove starter motor from vehicle. 2. Disconnect wire from solenoid field coil terminal. 3. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester (1). There should be continuity If OK, go to Step 4. If not OK, replace faulty starter motor assembly. 4. Check for continuity (2) between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5397 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5398 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5399 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5400 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5401 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5402 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5403 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5404 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5405 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5406 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5407 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5408 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5409 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5410 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5411 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5412 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5413 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5414 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5415 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5416 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5417 Auxiliary Power Outlet: Connector Views Power Outlet Power Outlet - Console (Except Base) Power Outlet - Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5418 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5419 8w-41-3 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5420 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel Auxiliary Power Outlet: Description and Operation Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5423 Auxiliary Power Outlet: Description and Operation Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5424 Auxiliary Power Outlet: Description and Operation Power Outlet - Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5425 Auxiliary Power Outlet: Description and Operation Power Outlet - Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5426 Auxiliary Power Outlet: Testing and Inspection POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5427 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation Electrical Accessory Panel: Description and Operation The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5431 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5432 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5433 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 5442 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems Intermittent Component Operation > Page 5448 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5449 Fuse: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5450 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5451 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5452 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5453 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5456 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5457 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5458 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5459 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5460 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5461 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5462 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5463 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5464 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5465 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5466 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5467 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5468 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5469 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5470 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5471 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5472 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5473 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5474 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5475 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5476 Fuse: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5477 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5478 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5479 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5480 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5484 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5485 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5486 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5487 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5490 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5491 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5492 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5493 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5494 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5495 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5496 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5497 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5498 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5499 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5500 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5501 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5502 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5503 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5504 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5505 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5506 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5507 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5508 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5509 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5510 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5511 Fuse Block: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5512 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5513 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5514 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5515 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5519 Battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5520 Power Distribution Module: Diagrams Module - Totally Integrated Power C1 Module - Totally Integrated Power C10 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5521 Module - Totally Integrated Power C2 Module - Totally Integrated Power C3 Module - Totally Integrated Power C4 Module - Totally Integrated Power C5 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5522 Module - Totally Integrated Power C6 Module - Totally Integrated Power C7 Module - Totally Integrated Power C8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5523 Module - Totally Integrated Power C9 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5526 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5527 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5530 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5531 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5532 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5543 Battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5544 Power Distribution Module: Diagrams Module - Totally Integrated Power C1 Module - Totally Integrated Power C10 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5545 Module - Totally Integrated Power C2 Module - Totally Integrated Power C3 Module - Totally Integrated Power C4 Module - Totally Integrated Power C5 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5546 Module - Totally Integrated Power C6 Module - Totally Integrated Power C7 Module - Totally Integrated Power C8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5547 Module - Totally Integrated Power C9 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5550 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5551 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5554 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5555 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5556 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5563 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5564 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5565 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5566 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5567 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5568 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5569 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5570 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5571 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5572 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5576 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5577 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5578 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5579 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5580 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5581 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5582 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5583 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5584 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5585 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5607 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5608 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5609 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5610 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5611 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5612 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5613 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5614 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5615 Auxiliary Power Outlet: Connector Views Power Outlet Power Outlet - Console (Except Base) Power Outlet - Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5616 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5617 8w-41-3 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5618 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel Auxiliary Power Outlet: Description and Operation Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5621 Auxiliary Power Outlet: Description and Operation Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5622 Auxiliary Power Outlet: Description and Operation Power Outlet - Instrument Panel A cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel. The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if inoperative or damaged, they must be replaced. The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the Integrated Power Module (IPM) when the ignition switch is in the Accessory or Run positions. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Instrument Panel > Page 5623 Auxiliary Power Outlet: Description and Operation Power Outlet - Console Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5624 Auxiliary Power Outlet: Testing and Inspection POWER OUTLET For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Page 5625 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation Electrical Accessory Panel: Description and Operation The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5629 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5630 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Description and Operation > Page 5631 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: Customer Interest Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 5640 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation Fuse: All Technical Service Bulletins Electrical Systems - Intermittent Component Operation NUMBER:08-016-06 REV. A GROUP: Electrical DATE: July 18, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-016-06, DATED MARCH 22, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF A VEHICLE BODY STYLE. SUBJECT: Intermittent Operation Of Electrical Components Due To Ignition Off Draw (IOD) Fuse Not Being Fully Seated MODELS: 2007 (PM) Caliber **2007 (MK-49) Compass** 2006 - 2007 (DHIDRID1) Ram Truck 2006 - 2007 (PT) Chrysler PT Cruiser DISCUSSION: The Ignition Off Draw (IOD) fuse is used to prevent battery discharge during shipping and long term storage of the vehicles. The IOD fuse is located in the Total Integrated Power Module (TI PM). If the fuse is not completely inserted partial contact of the fuse terminals could occur. When the vehicle is prepped for customer delivery, ensure that the fuse is fully engaged (Fig. 1). The IOD fuse must also be fully released to prevent battery drain from occurring when the vehicle is stored. When the IOD fuse holder is depressed into the carrier, an initial distinct detent will be felt to overcome the "pre-hold position". You must then continue to push straight down on the IOD pre-holder until no further downward movement is encountered. NOTE: If the fuse is not pushed down symmetrically, two detents MAY be felt as each side snaps past the pre-hold position. Push down until no further downward movement is encountered. On 2006 and 2007 PT and PM vehicles the circuits fed by the IOD fuse are: Radio, Security module & siren (BUX), Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Power Mirrors, Clock, Memory Seat, Amplifier, CCN wake-up with ignition off and Homelink. On 2006 and 2007 DR, DH or D1 vehicles the circuits fed by the IOD fuse are: Radio, EVIC, Wireless Control Module (RKE & SKREEM), Hands Free Module, Satellite Radio, Video Screen, CCN wake-up with ignition off, Underhood Lamp, CCN Interior Lighting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 08-016-06A > Jul > 06 > Electrical Systems - Intermittent Component Operation > Page 5646 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5647 Fuse: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5648 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5649 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5650 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5651 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 Fuse: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5674 Fuse: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5675 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5676 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5677 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Page 5678 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations Fuse Block: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5682 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5683 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5684 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Page 5685 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5709 Fuse Block: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5710 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5711 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5712 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Page 5713 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5717 Battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5718 Power Distribution Module: Diagrams Module - Totally Integrated Power C1 Module - Totally Integrated Power C10 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5719 Module - Totally Integrated Power C2 Module - Totally Integrated Power C3 Module - Totally Integrated Power C4 Module - Totally Integrated Power C5 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5720 Module - Totally Integrated Power C6 Module - Totally Integrated Power C7 Module - Totally Integrated Power C8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5721 Module - Totally Integrated Power C9 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5724 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5725 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5728 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5729 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5730 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations Power Distribution Module: Locations Left Front Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5741 Battery Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5742 Power Distribution Module: Diagrams Module - Totally Integrated Power C1 Module - Totally Integrated Power C10 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5743 Module - Totally Integrated Power C2 Module - Totally Integrated Power C3 Module - Totally Integrated Power C4 Module - Totally Integrated Power C5 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5744 Module - Totally Integrated Power C6 Module - Totally Integrated Power C7 Module - Totally Integrated Power C8 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 5745 Module - Totally Integrated Power C9 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM is located in the engine compartment, next to the battery and connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. The molded plastic IPM housing includes a base and cover. The IPM cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This IPM housing base and cover are secured in place via bolts to the left front fender support assembly. Replaceable components of the IPM assembly are broken down into the following components: - The Power Distribution Center (PDC) - The IPM cover - The Front Control Module (FCM) - Complete IPM assembly that includes all three parts All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 5748 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is a micro controller located in the left front corner of the engine compartment. It is necessary to position the Integrated Power Module (IPM) aside in order to access the front control module on this vehicle. The FCM mates to the Power Distribution Center (PDC) to form the IPM. The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The FCM controls power to some of the vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit. As messages are sent over the Programmable Communications Interface (PCI) data bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the FCM: - Headlamp Power with Voltage Regulation - Windshield Wiper "ON/OFF" Relay Actuation - Windshield Wiper "HI/LO" Relay Actuation - Windshield Washer Pump Motor - Fog Lamp Relay Actuation - Park Lamp Relay Actuation - Horn Relay Actuation The following inputs are Received/Monitored by the FCM: - B+ Connection Detection - Power Ground - Ambient Temperature Sensing - Ignition Switch Run - Washer Fluid Level Switch - Windshield Wiper Park Switch - PCI Data Bus Circuit Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 5749 Power Distribution Module: Testing and Inspection FRONT CONTROL MODULE The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus network and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any FCM related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool. The most reliable, efficient, and accurate means to diagnose the FCM requires the use of an appropriate scan tool and the proper Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove cove (4) by loosening the cover screw (1). 3. Remove the B+ terminal nut from the Integrated Power Module (IPM) B+ terminal. Remove the B+ cable from the IPM. 4. Disconnect the gray connector from the IPM. 5. Remove the IPM retaining bolt (2) and screw (3). 6. Grasp the IPM with two hands and slide the assembly in the direction shown to free the module from its mounting bracket. Position the assembly upside down to access the electrical connectors located on the bottom of the unit. 7. Disconnect the electrical connectors by depressing the locking tab and rotating the connector arm out-board, until the connector is free from the IPM assembly. Be certain to pull the connectors straight off. 8. Remove the IPM from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5752 1. Position the Integrated Power Module (IPM) into the vehicle. NOTE: Integrated power module electrical connectors are color coded to ease location reference. 2. Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the IPM assembly. 3. Grasp the IPM (3) with two hands and install the assembly onto the battery tray (2) making sure to line up the tabs with the retaining slots in the tray (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5753 4. Install the IPM retaining bolt (2) and screw (3). 5. Connect the gray connector on the IPM housing. 6. Install the B+ terminal cable and nut on the B+ terminal. 7. Install the IPM cover (4) and tighten the retaining screw (1). 8. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 5754 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the battery negative cable (3). 2. Partially remove the Integrated Power Module (IPM) (4) from the engine compartment. 3. Remove the Front Control Module (FCM) retaining screws. 4. Using both hands, separate the FCM from the IPM assembly disengaging the 49-way electrical connector and remove the FCM from the vehicle. INSTALLATION 1. Install the Front Control Module (FCM) onto the Integrated Power Module (IPM) (4) by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 7 in. lbs. 3. Install the IPM. 4. Connect the battery negative cable. 5. Verify normal vehicle operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Relay > Component Information > Description and Operation Power Distribution Relay: Description and Operation RELAY-TRAILER TOW All vehicles are equipped with two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced. The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays can be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5761 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5762 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5763 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5764 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5765 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5766 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5767 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5768 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5769 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5770 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Relay Box: Locations Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5774 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5775 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5776 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5777 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5778 Module - Totally Integrated Power (Rear View) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5779 Relay Box: Application and ID Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5780 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5781 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5782 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 5783 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation IOD FUSE All vehicles are equipped with an Ignition-Off Draw (IOD) fuse (1) that is disconnected within the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the IPM as part of the preparation procedures performed just prior to new vehicle delivery. A laser printed fuse layout map is integral to the IPM cover to ensure proper fuse identification. The IOD fuse (1) is a 20 ampere mini blade-type fuse, located in fuse cavity # 51. The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in the IPM cavity, and as a fuse holder that conveniently stores the fuse in the same cavity after it has been disconnected. CIRCUITS INCLUDED WITH IOD FUSE - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps Radio - Underhood Lamp The term Ignition-Off Draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from Integrated Power Module (IPM) fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application Alignment: Customer Interest Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5797 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5798 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application Alignment: All Technical Service Bulletins Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5804 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5805 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5806 Alignment: By Symptom Technical Service Bulletin # 02-001-07A Date: 070331 Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5807 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5808 For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 02-001-07A Date: 070331 Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5809 This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5810 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5811 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 02-001-07A Date: 070331 Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5812 MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5813 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 5814 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5815 Alignment: Specifications ALIGNMENT NOTE: All alignment specifications are in degrees. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5816 SPECIFICATIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5817 Alignment: Description and Operation WHEEL ALIGNMENT DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. OPERATION ^ CASTER is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns ^ CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire ^ TOE is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification causes unstable steering, uneven tire wear and steering wheel off-center. The wheel toe position is the final front wheel alignment adjustment ^ THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5818 Alignment: Testing and Inspection PREALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Road test the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5819 Alignment: Service and Repair CAMBER, CASTER AND TOE ADJUSTMENT AND CURB HEIGHT MEASUREMENT Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets (1). CASTER Moving the front of rear position of the lower control arm in or out, will change the caster angle and camber angle significantly. To maintain the camber angle while adjusting caster, move one pivot bolt of the lower control arm in or out. Then move the other pivot bolt of the lower control arm in the opposite direction. To increase positive caster angle, move the rear position of the lower control arm inward (toward the engine). Move the front of the lower control arm outward (away from the engine) slightly until the desired camber angle is obtained. CAMBER Move both pivot bolts of the lower control arm together in or out. This will change the camber angle significantly and little effect on the caster angle. After adjustment is made tighten the lower control arm nuts to proper torque specification. TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5820 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheels with the front wheels in the straight-ahead position. 2. Loosened the tie rod jam nut (1). Note: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (2) as necessary. 4. Tighten the tie rod jam nut (1) to 127 Nm ( 94 ft lbs ). 5. Verify the specifications. 6. Turn off engine. CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all alignment adjustments made with the vehicle at its required curb height specification. Vehicle height is to be checked with the vehicle on a flat, level surface, preferably a vehicle alignment rack. The tires are to inflated to the recommended pressure. All tires are to be the same size as standard equipment. Vehicle height is checked with the fuel tank full if fuel, and no passenger or luggage compartment load. Inspect the vehicle for bent or weak suspension components. Compare the parts tag on the suspect coil spring(s) to the parts book and the vehicle sales code, checking for a match. Once removed from the vehicle, compare the coil spring height to a correct new or known good coil spring. The heights should vary if the suspect spring weak, Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5821 1. Front - On each side of the vehicle measure the distance from the center of the rear lower control arm bolt (1) to the ground (2). Record the measurement. Next measure the distance from the spindle center (3) to the ground (4). Recod measurement. 2. Take the two measurements and subtract them to get the ride height specification. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 5822 3. Rear 4X2 - On each side of the vehicle, measure the distance at the axle tube (1) to the jounce bumper flange (2). 4. Rear 4X4 - On each side of the vehicle, measure the distance at the jounce pad welded to the axle tube (1) to the jounce bumper flange (2). 5. Compare the measurements to the specifications listed in the following Curb Height Specifications chart. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5828 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5829 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5830 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal (LD) 4X2 & 4X4 KNUCKLE REMOVAL (LD) 4X2 & 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 9360. 5. Remove the halfshaft nut (4X4 only). 6. Remove the upper ball joint nut. Separate the ball joint (4) from the knuckle (6) with Remover 9360 (5) CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5837 7. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 (2). 8. Remove the steering knuckle (1) from the vehicle. 9. Remove the hub/bearing from the steering knuckle on the bench. (HD) 4X2 KNUCKLE REMOVAL (HD) 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 9360. 5. Remove the upper ball joint nut. Separate the ball joint from the knuckle with Remover 9360. CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the lower ball joint nut. Separate the ball joint from the knuckle with puller 8677 and remove the knuckle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5838 7. Remove the hub/bearing from the steering knuckle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5839 Front Steering Knuckle: Service and Repair Installation (LD) 4X2 & 4X4 KNUCKLE INSTALLATION (LD) 4X2 & 4X4 CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (an additional 90° turn is required) and the lower ball joint nut to 52 Nm (38 ft. lbs.)(an additional 90° turn is required). 4. Remove the hydraulic jack from the lower suspension arm (4). 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor (if equipped) and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignment. (HD) 4X2 KNUCKLE INSTALLATION (HD) 4X2 CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 176 Nm (130 ft. lbs.). 2. Install the knuckle onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts. Install and tighten the upper ball joint nut, to 54 Nm (40 ft. lbs.). Then Install and tighten the lower ball joint nut to 135 Nm (100 ft. lbs.). 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 7. Install the wheel and tire assembly. 8. Remove the support and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5840 9. Perform a wheel alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5846 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5847 Power Steering Fluid: Specifications Power Steering Fluid Type .................................................................................................................. .......................................................... Mopar ATF+4 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 5848 Power Steering Fluid: Description and Operation FLUID DESCRIPTION NOTE: It is normal that some pressure will build up inside the reservoir, especially, with a warm vehicle. A slight popping noise upon removal of the cap is normal. The fluid level should read between the ADD and the FULL COLD marks. When the fluid is hot it should read between ADD and FULL HOT marks. Only add fluid when the vehicle is cold. The recommended fluid for the power steering system is Mopar ATF +4. Mopar ATF+4, when new is red in color. The ATF+4 is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition, As the vehicle is driven, the ATF+4 will begin to look darker in color and may eventually become brown. THIS IS NORMAL. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Flushing Power Steering System Power Steering Fluid: Service and Repair Flushing Power Steering System FLUSHING POWER STEERING SYSTEM Flushing is required when the power steering/hydraulic booster system fluid has become contaminated. Contaminated fluid in the steering/booster system can cause seal deterioration and affect steering gear/booster spool valve operation. NOTE: The engine should not be run so that all of the fluid is drained from the system. The pump should never be run without fluid. 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the return line from the pump. NOTE: If vehicle is equipped with a hydraulic booster remove both return lines from the pump. 3. Plug the return line port/ports at the pump. 4. Position the return line/lines into a large container to catch the fluid. 5. While an assistant is filling the pump reservoir start the engine. 6. With the engine running at idle turn the wheel back and forth. NOTE: Do not contact or hold the wheel against the steering stops. 7. Run a quart of fluid through the system then stop the engine and install the return line/lines. 8. Fill the system with fluid and perform Steering Pump Initial Operation. 9. Start the engine and run it for fifteen minutes then stop the engine. 10. Remove the return line/lines from the pump and plug the pump port/ports. 11. Pour fresh fluid into the reservoir and check the draining fluid for contamination. If the fluid is still contaminated, then flush the system again. 12. Install the return line/lines and perform Steering Pump Initial Operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Service and Repair > Flushing Power Steering System > Page 5851 Power Steering Fluid: Service and Repair Power Steering Fluid Level Checking POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. There are two ranges listed on the dipstick, COLD and HOT. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the cold range. When the fluid is hot, fluid level is allowed to read up to the highest end of the HOT range. Only add fluid when the vehicle is cold. Use only Mopar ATF+4. Do not overfill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair Power Steering Fluid Cooler: Service and Repair FLUID COOLER REMOVAL 1. Drain and siphon the power steering fluid. 2. Disconnect the return and supply hoses connected to the power steering fluid cooler. 3. Remove the mounting bracket bolts (2) securing the fluid cooler (1) to the brace. (V6&V8;) 4. Remove the mounting bracket bolts (3) securing the fluid cooler (1) to the brace. (Diesel engine) 5. Remove the fluid cooler from the vehicle. INSTALLATION 1. Install the fluid cooler (1) to the vehicle. 2. Install the mounting bracket bolts (2) securing the fluid cooler (1) to the brace (V6&V8;) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Service and Repair > Page 5855 3. Install the mounting bracket bolts (3) securing the fluid cooler (1) to the brace (Diesel Engine). 4. Reclamp the return and supply hoses to the power steering fluid cooler (4). 5. Refill the power steering fluid. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair RESERVOIR REMOVAL 1. Drain and siphon the power steering fluid from the reservoir. 2. Remove the serpentine belt. 3. Remove the power steering pump. 4. Remove the reservoir mounting bolts. 5. Remove the reservoir. 6. Remove the rear bracket to the pump mounting bolts. INSTALLATION 1. Install the reservoir bracket to the pump housing. Do not reuse the o-rings (install new o-rings). Tighten bolts to 7 Nm (62 inch lbs.). NOTE: Ensure the reservoir is fully seated onto the pump. 2. Install the reservoir to the bracket/pump body 3. Install the reservoir mounting bolts. Tighten bolts to 13 Nm (120 inch lbs.). 4. Install the power steering pump. 5. Install the serpentine drive belt. 6. Fill the power steering pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Return Hose-Gear to Cooler Power Steering Line/Hose: Service and Repair Return Hose-Gear to Cooler RETURN HOSE - GEAR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the return hose at the cooler. 4. Disconnect the return hose (1) at the gear. 5. Remove the return hose from the routing clamp at the fan shroud and then remove from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reconnect the return hose (1) at the gear. Tighten the hose to 50 Nm (37 ft. lbs.). 4. Reattach the hose to the routing clip at the fan shroud. 5. Remove the support and lower the vehicle. 6. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Return Hose-Gear to Cooler > Page 5863 Power Steering Line/Hose: Service and Repair Pressure Hose PRESSURE HOSE REMOVAL 1. Drain and siphon the power steering system. 2. Raise and support the vehicle. 3. Disconnect the pressure hose at the pump. 4. Disconnect the pressure hose (2) at the gear. 5. Remove the pressure hose from the vehicle. INSTALLATION NOTE: Be sure to align the pressure hose so it does not contact the fan shroud or the frame rail. 1. Install the pressure hose to the vehicle. 2. Reconnect the pressure hose (2) at the gear. Tighten the hose to 32 Nm (23 ft. lbs.). 3. Reconnect the pressure hose at the pump. Tighten the hose to 31 Nm (23 ft. lbs.). 4. Remove the support and lower the vehicle. 5. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Return Hose-Gear to Cooler > Page 5864 Power Steering Line/Hose: Service and Repair Return Hose - Reservoir to Cooler RETURN HOSE-RESERVOIR TO COOLER REMOVAL 1. Drain and siphon the power steering system. 2. Disconnect the return hose at the reservoir. 3. Raise and support the vehicle. 4. Remove the return hose from the routing clamp at the fan shroud. 5. Disconnect the return hose at the cooler. 6. Remove the hose from the vehicle. INSTALLATION 1. Install the return hose to the vehicle. 2. Reconnect the return hose at the cooler. 3. Reattach the hose to the routing clip at the fan shroud. 4. Remove the support and lower the vehicle. 5. Reconnect the return hose at the reservoir. 6. Refill the power steering system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications TORQUE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5868 Power Steering Pump: Description and Operation PUMP DESCRIPTION CAUTION: MOPAR ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The pump is connected to the steering gear via the pressure hose and the return hose. The pump shaft has a pressed on pulley that is belt driven by the crankshaft pulley All vehicles are equipped with a power steering fluid cooler. NOTE: Power steering pumps are not interchangeable with pumps installed on other vehicles. OPERATION Hydraulic pressure is provided for the power steering gear by the belt driven power steering pump (2). The power steering pumps are constant flow rate and displacement, vane-type pumps. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 5869 Power Steering Pump: Testing and Inspection PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and the reservoir o-rings can be replaced. Check for leaks in the following areas: ^ Pump shaft seal behind the pulley ^ Pump to reservoir O-ring ^ Reservoir cap ^ Pressure and return lines ^ Flow control valve fitting Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation Power Steering Pump: Service and Repair Initial Operation POWER STEERING PUMP - INITIAL OPERATION WARNING: THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS. CAUTION: MOPAR ATF+4 is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. 1. Turn steering wheel all the way to the left. 2. Fill reservoir up to FULL HOT level and crank engine until it just starts. (DO NOT TURN STEERING WHEEL). Then turn vehicle off. And recheck fluid level, to Full COLD. 3. Crank engine again until it just starts, (DO NOT MOVE STEERING WHEEL). and turn vehicle off. Recheck fluid level to Full COLD. 4. Turn engine on again, (DO NOT MOVE STEERING WHEEL) and let the vehicle idle for 5 minutes. If possible apply a 20 in-Hg vacuum to the reservoir, while engine is idling. 5. Turn engine off and recheck fluid level, to FULL COLD. 6. If the Steering gear is replaced ensure reservoir is at FULL HOT level, start engine and turn wheel to left. Stop Engine and recheck fluid level to FULL HOT. Start engine and turn wheel to the right. Stop engine and check fluid level is at FULL COLD. 7. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 8. Start the engine. With the engine idling maintain the fluid level. 9. Raise the front wheels off the ground. 10. Slowly turn the steering wheel lock-to-lock 20 times with the engine off while checking the fluid level. NOTE: For vehicles with long return lines or oil coolers turn wheel 40 times. 11. Lower the front wheels and let the engine idle for two minutes. 12. Turn the steering wheel in both direction and verify power assist and quiet operation of the pump. If the fluid is extremely foamy or milky looking, allow the vehicle to stand a few minutes and repeat the procedure. CAUTION: Do not run a vehicle with foamy fluid for an extended period. This may cause pump damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation > Page 5872 Power Steering Pump: Service and Repair Removal and Installation PUMP REMOVAL GAS ENGINE 1. Drain and siphon the power steering fluid from the reservoir. 2. Remove the serpentine belt. CAUTION: Do not remove the fitting on the pump that the high pressure hose screws into. The fitting may come loose unless it is backed up using another wrench. If the fitting does come loose, it must be retightened before continuing. (57 - 67 Nm, 40 - 50 ft. lbs.). If this fitting comes out of the pump body, the internal spring and valve parts will fall out of the pump and they cannot be reinstalled properly. If this occurs the pump needs to be replaced with a new pump. 3. Disconnect the return hose (3). 4. Disconnect the pressure hose (4). 5. Access to remove the three bolts securing the pump to the cylinder head can be gained thru the pulley holes (1). INSTALLATION 1. Align the pump with the mounting holes in the left cylinder head. 2. Install 3 pump mounting bolts through the pulley access holes (1). Tighten the bolts to 28 Nm (21 ft. lbs.). 3. Reconnect the pressure line (4) and return hose (3) to the pump and reservoir (2). Tighten the pressure line to 31 Nm (23 ft. lbs.). 4. Install the serpentine drive belt. 5. Fill the power steering pump. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation > Page 5873 Power Steering Pump: Service and Repair Pulley PULLEY REMOVAL CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Remove the power steering pump assembly (1). 2. Remove the pulley (2) from the pump using (OTC 7185) power steering pulley removal tool or equivalent (3). INSTALLATION CAUTION: Do not reuse the old power steering pump pulley it is not intended for reuse. A new pulley must be installed if removed. 1. Replace the pulley (2) if it's bent, cracked, or loose. 2. Install the pulley (2) on the pump (1) using (OTC 7771) power steering pulley installation tool or equivalent (3) making sure it is flush with the end of the shaft. Ensure the tool and pulley remain aligned with the pump shaft. 3. Install the power steering pump assembly. 4. Run engine until warm (5 minutes) and note any belt chirp. If chirp exists, move pulley outward approximately 0.5 mm (0.020 inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact mounting bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Left Side Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5878 Switch - Power Steering Pressure (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5879 Power Steering Pressure Switch: Description and Operation SWITCH-POWER STEERING PRESSURE DESCRIPTION A pressure sensing switch is used in the power steering system. It is mounted on the high-pressure steering hose. This switch will only be used on HD vehicles with the 5.7L engines. There is no pressure switch used for the 3.7L, 4.7L, 5.9L Diesel engine or the 5.7L LD vehicle pump. OPERATION The switch is used on the 5.7L V8 engines HD vehicles only. The power steering pressure switch provides an input to the Powertrain Control Module (PCM). This input is provided during periods of high steering pump load and low engine rpm; such as during parking maneuvers. The PCM increases the idle speed through the Idle Air Control (IAC) motor. This is done to prevent the engine from stalling under the increased load. When steering pump pressure exceeds 3275 kPa ± 690 kPa (475 psi ± 100 psi), the Normally Closed (NC) switch will open and the PCM will increase the engine idle speed. This will prevent the engine from stalling. When pump pressure drops to approximately 1379 kPa (200 psi), the switch circuit will reclose and engine idle speed will return to its previous setting. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations > Page 5880 Power Steering Pressure Switch: Service and Repair SWITCH-POWER STEERING PRESSURE REMOVAL-5.7L-HD VEHICLES ONLY The power steering pressure switch (5) is installed in the power steering high-pressure hose (5). 1. Disconnect electrical connector from power steering pressure switch. 2. Place a small container or shop towel beneath switch to collect any excess fluid. 3. Remove switch. Use backup wrench on power steering line to prevent line bending. INSTALLATION-5.7L-HD VEHICLES ONLY This switch is used only with the 5.7L V8 engines HD vehicles only. 1. Install power steering switch (5) into power steering line (5). 2. Tighten to 8 - 11 Nm (70 - 100 inch lbs.) torque. 3. Connect electrical connector to switch. 4. Check power steering fluid and add as necessary. 5. Start engine and again check power steering fluid. Add fluid if necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 5886 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 5887 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover Steering Column Cover: Service and Repair Steering Column Opening Cover REMOVAL 1. Remove the park brake release handle. 2. Remove the two screws that secure the bottom of the steering column opening cover (3) to the instrument panel. 3. Using a trim stick C-4755 or equivalent, release the two retainer clips that secure the top of the steering column opening cover (2) to the instrument panel and remove the cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 5895 4. Remove the screws and remove the knee blocker. INSTALLATION 1. Install the knee blocker (2) and install the screws (1). 2. Position the steering column opening cover (2) to the instrument panel and fully engage the two upper retainer clips to the instrument panel. 3. Install the two screws that secure the steering column opening cover to the instrument panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 5896 4. Install the park brake release handle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 5897 Steering Column Cover: Service and Repair Steering Column Opening Support Bracket REMOVAL 1. Remove the steering column opening cover from the instrument panel (1). 2. Remove the hood release handle from the steering column opening support bracket (2). 3. Disengage the retaining tabs that secure the data link connector (3) to the steering column opening support bracket and remove the data link connector from the bracket. 4. Remove the two screws (4) that secure the steering column opening support bracket (3) to the instrument panel (2). 5. Slide the steering column opening support bracket upward to disengage the two locating tabs (1) and remove the bracket. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Steering Column Opening Cover > Page 5898 1. Position the steering column opening bracket (3) onto the instrument panel (2) and engage to the two locating tabs (1). 2. Install the two screws (4) that secure the steering column opening bracket to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Position the data link connector (3) into the opening in the steering column opening bracket (2) and fully engage the retaining tabs that secure the connector to the bracket. 4. Install the hood release handle. 5. Install the steering column opening cover onto the instrument panel (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair Tilt Wheel Handle: Service and Repair TILT LEVER KNOB RELEASE REMOVAL 1. Remove the screw (1) securing the tilt lever knob (2). 2. Remove the steering column opening cover. 3. Remove the lower shroud. NOTE: Use special care not to pry on the clockspring electrical connector when removing or installing the mounting screw located next to the clockspring. 4. Remove the two mounting screws (1) from the tilt lever knob release bracket (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Page 5902 5. Unseat the rod (2) from the release lever assembly INSTALLATION 1. Route the rod (2) into the tilt lever release knob bracket (1). 2. Install the tilt lever release knob bracket (3) to the column and install the two new mounting screws (1). Tighten the two screws to 4.5 Nm (40 inch lbs.). 3. Install the lower shroud. 4. Install the steering column opening cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Handle > Component Information > Service and Repair > Page 5903 5. Install the tilt lever knob (2) and screw (1). Tighten the screw to 4.5 Nm (40 inch lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications GEAR - INDEPENDENT FRONT SUSPENSION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications > Page 5907 Steering Gear: Description and Operation GEAR - INDEPENDENT FRONT SUSPENSION DESCRIPTION A rack and pinion steering gear is made up of two main components, the pinon shaft and the rack. The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Bushing Steering Gear: Service and Repair Bushing BUSHING REMOVAL 1. Remove the steering gear. CAUTION: Do not overtighten the vise on the gear case. 2. Mount the steering gear in a soft jawed vise. NOTE: If the bushings are seized a brass punch can be used to remove the bushings from the gear using care not to strike the gear. 3. Remove the front mounting bushings. 4. Remove the rear mounting bushings. 5. Remove the steering gear from the vise and place it on the bench. INSTALLATION NOTE: Coat all bushings with a thin rubber lubricate oil prior to installation. NOTE: A rubber mallet can be used to assist in the installation of the bushings once lubricated. 1. Coat the rear bushings with a thin rubber lubricate oil then install the rear bushings using a rubber mallet to seat the bushings in the gear. 2. Coat the front bushings with a thin rubber lubricate oil then install the front bushings using a rubber mallet to seat the bushings in the gear. 3. Install the steering gear. 4. Adjust the toe position (if necessary). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Bushing > Page 5910 Steering Gear: Service and Repair Gear Removal and Installation GEAR-INDEPENDENT FRONT SUSPENSION REMOVAL NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 1. Lock the steering wheel. 2. Drain and siphon the power steering fluid from the reservoir. 3. Raise the vehicle. 4. Remove and discard the steering coupler pinch bolt. 5. Remove the power steering hoses from the rack & pinion. 6. Remove the tire and wheel assembly 7. Remove the tie rod end nuts and separate tie rod ends from the knuckles with puller 8677. 8. Remove the skid plate. 9. Remove the rack & pinion mounting bolts (1). 10. Remove the rack & pinion (2) from the vehicle. INSTALLATION NOTE: Before installing gear inspect bushings and replace if worn or damaged. NOTE: In the frame there are two holes for the mounting of the steering gear, one is slotted and one is round. When tightening the gear to specifications make sure to tighten the mounting bolt with the hole first to avoid movement of the steering gear. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Bushing > Page 5911 1. Install the gear on the front crossmember and tighten the mounting bolts (2) to 319 Nm (235 ft. lbs.) LD torque specification. Or tighten the mounting bolts to 251 Nm (185 ft. lbs.) 4X2 HD torque specification. 2. Slide the shaft coupler onto the gear. Install new pinch bolt and tighten to 49 Nm (36 ft. lbs.). 3. Clean and dry the tie rod end studs and the knuckle tapers. 4. Install the tie rod ends into the steering knuckles and tighten the nuts to 61 Nm (45 ft. lbs.) then an additional 90°. 5. Install the pressure power steering hose to the steering gear and tighten to 32 Nm (23 ft. lbs.). 6. Install the return power steering hose to the steering gear and tighten to 50 Nm (37 ft. lbs.) LD torque specification. Or tighten the mounting bolts to 54 Nm (40 ft. lbs.) 4X2 HD torque specification. 7. Install the front skid plate. 8. Install the tire and wheel assembly. 9. Remove the support and lower the vehicle. 10. Fill the system with fluid. 11. Adjust the toe position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling Steering Shaft Coupler: Service and Repair Upper Steering Coupling UPPER STEERING COUPLING REMOVAL 1. Disconnect the negative battery cable. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 2. Lock the steering wheel with the tire in the straight position. 3. Remove and discard the lower pinch bolt. 4. Lower the steering coupler shaft from the column. 5. Remove the upper steering coupling shaft (2) seal by pushing in the four tags (1) securing it to the panel. 6. Remove and discard the lower coupler pinch bolt (1) from the lower steering coupling shaft (1). 7. Remove the upper steering coupling shaft (3) from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5916 1. Install the upper steering coupling shaft (3) to the vehicle. 2. Install the upper steering coupling shaft seal (2) by pushing it in securing the four tangs (1) to the panel. NOTE: A new steering coupling shaft pinch bolt for the upper and lower shafts must be used. 3. Install the steering coupler shaft (1) to the column. 4. Install the upper pinch bolt (3) use new bolt and tighten to 57 Nm (42 ft. lbs.). 5. Install the shaft to the lower coupler (1). 6. Install the lower pinch bolt (1) use new bolt and tighten to 57 Nm (42 ft. lbs.). 7. Unlock the steering wheel. 8. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5917 Steering Shaft Coupler: Service and Repair Lower Steering Coupling LOWER STEERING COUPLING REMOVAL ALL LD & HD EXCEPT 4X4 HD 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 3. Lock the steering wheel with the tire in the straight position. 4. Remove the left front tire and wheel assembly. 5. Mark both coupler connections for proper installation. 6. Remove and discard the upper coupler pinch bolt. 7. Remove and discard the lower coupler pinch bolt. 8. Remove the lower steering shaft coupler. 4X4 HD 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. NOTE: The steering column on vehicles with an automatic transmission may not be equipped with an internal locking shaft that allows the ignition key cylinder to be locked with the key. Alternative methods of locking the steering wheel for service will have to be used. 3. Lock the steering wheel with the tire in the straight position. 4. Remove the left front tire and wheel assembly. 5. Remove and discard the upper coupler pinch bolt (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5918 6. Remove and discard the lower coupler pinch bolt (2). 7. Remove the lower steering shaft coupler (3). INSTALLATION ALL LD & HD EXCEPT 4X4 HD 1. Install the coupler to the steering rack & pinion using the marks made in the removal process. 2. Install the coupler to the intermediate shaft using the marks made in the removal process. NOTE: New pinch bolts must be used for reinstallation. 3. Install the lower pinch bolt and tighten to 57 Nm (42 ft. lbs.). SRT10. Tighten to 38 Nm (28 ft. lbs.). 4. Install the upper pinch bolt and tighten to 57 Nm (42 ft. lbs.). 5. Install the left front tire and wheel assembly. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Unlock the steering wheel. 4X4 HD Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Service and Repair > Upper Steering Coupling > Page 5919 1. Install the coupler (2) to the steering gear (3). 2. Install the coupler (3) to the intermediate shaft (2). NOTE: New pinch bolts must be used for reinstallation. 3. Install the lower pinch bolt (3) and tighten to 28 Nm (250 inch lbs.). 4. Install the upper pinch bolt (1) and tighten to 57 Nm (42 ft. lbs.). 5. Install the left front tire and wheel assembly. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Unlock the steering wheel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair STEERING WHEEL REMOVAL 1. Disable and remove the driver's side airbag. 2. Partially remove the steering wheel bolt and leave the bolt in the column. 3. Install puller CJ981 (2) or equivalent using the top of the bolt to push on. 4. Remove and discard the steering wheel bolt. 5. Remove the steering wheel (1). INSTALLATION NOTE: Do not reuse the old steering wheel bolt (a new bolt must be used) 1. Install steering wheel to the column NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation. 2. Install the new steering wheel bolt. Tighten the bolt to 61 Nm (45 ft. lbs.). 3. Install the driver's side air bag. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection OUTER TIE ROD END NOTE: If the outer tie rod end is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator solidly to the vehicle steering knuckle and then zero the dial indicator. 4. Position indicator plunger on the topside of the outer tie rod end. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the outer tie rod end. 5. Position a pry bar in order to pry downwards on the outer tie rod end. 6. If the travel exceeds 0.5 mm (0.020 inch), replace the outer tie rod end. 7. If the outer tie rod end is within specs reinstall the front tires. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 5927 Tie Rod End: Service and Repair OUTER TIE ROD END REMOVAL NOTE: Do not twist the boot anytime during removal or installation. 1. Loosen the jam nut (3). 2. Remove the outer tie rod end nut from the ball stud. 3. Separate the tie rod ball stud (1) from the knuckle with Remover 9360 (2). 4. Unthread the outer tie rod end (1) from the inner tie rod. INSTALLATION - OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end (3) onto the inner tie rod (2), to it's original position. 2. Install the outer tie rod end (3) into the steering knuckle. 3. Tighten the ball stud nut on the ball stud to 61 Nm (45 ft. lbs.) then an additional 90°. 4. Set wheel toe pattern. 5. Tighten jam nut (1) to 127 Nm (94 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 5928 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Wear Limit ........................................................................................................................................... .................................................. 0.5 mm (0.020 inch) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint Ball Joint: Testing and Inspection Lower Ball Joint LOWER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Mount a dial indicator solidly to the topside of the lower control arm and then zero the dial indicator. 3. Position the indicator plunger against the bottom surface of the steering knuckle. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle. 4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly. 5. If the travel exceeds 0.5 mm (0.020 inch), replace the lower ball joint. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Lower Ball Joint > Page 5935 Ball Joint: Testing and Inspection Upper Ball Joint UPPER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator solidly to the frame and then zero the dial indicator. 4. Position dial indicator plunger on the topside of the upper ball joint. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the ball joint. NOTE: Use care not to pry or tear the ball joint boot (5), when checking the free play. 5. Position a pry bar between the steering knuckle and the upper control arm. Pry upwards on the upper control arm. 6. If the travel exceeds 0.5 mm (0.020 inch), replace the upper ball joint. 7. If the upper ball joint is within specs reinstall the front tires. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint Ball Joint: Service and Repair Lower Ball Joint 4X2 (LD) LOWER BALL JOINT REMOVAL 4X2 (LD) 1. Remove the tire and wheel assembly. 2. Remove the brake caliper and rotor. 3. Disconnect the tie rod from the steering knuckle. 4. Separate the upper ball joint from the knuckle using remover 9360. 5. Remove the lower ball joint nut and separate the lower ball joint from the steering knuckle (1) using puller 8677 (2). NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 6. Press the ball joint from the lower control arm using special tools C4212F (PRESS) (1), 88366 (DRIVER) (2) and 86922 (RECEIVER) (3). 4X2 (HD) LOWER BALL JOINT REMOVAL 4X2 (HD) 1. Remove the tire and wheel assembly 2. Remove the brake caliper and rotor. 3. Disconnect the tie rod from the steering knuckle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5938 4. Remove the steering knuckle. 5. Remove the snap ring (3), from the lower ball joint (2). NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 6. Press the ball joint (3) from the lower control arm using special tools C4212F (PRESS) (1), 97762 (RECEIVER) (4) and 86983 (DRIVER) (2). 4X2 (LD) LOWER BALL JOINT INSTALLATION 4X2 (LD) NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5939 1. Install the ball joint (4) into the control arm (3) and press in using special tools C4212F (press) (1), 86981 (driver) (2) and 86983 (receiver) (5). 2. Stake the ball joint flange in four evenly spaced places around the ball joint flange, using a punch and hammer. 3. Install the steering knuckle. 4. Install the tie rod end into the steering knuckle. 5. Install the brake caliper and rotor. 6. Install the tire and wheel assembly. 7. Check the vehicle ride height. 8. Perform a wheel alignment. 4X2 (HD) LOWER BALL JOINT INSTALLATION 4X2 (HD) NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the ball joint (3) into the control arm (4) and press in using special tools C4212F (press) (1), 97761 (driver) (2) and 86983 (receiver) (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5940 2. Replace the snap ring (3). 3. Install the steering knuckle. 4. Install the tie rod end into the steering knuckle. 5. Install the brake caliper and rotor. 6. Install the tire and wheel assembly. 7. Check the vehicle ride height. 8. Perform a wheel alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5941 Ball Joint: Service and Repair Upper Ball Joint UPPER BALL JOINT REMOVAL 1. Raise vehicle and support the axle. 2. Remove the tire and wheel. 3. Remove the upper ball joint retaining nut. 4. Separate the upper ball joint (4) from the knuckle (6) using separator #9360 (5). 5. Remove the wheel speed sensor wire from the knuckle (HD) and from the upper control arm (LD). 6. Move the knuckle out of the way to allow ball joint removal tool access. 7. Remove the ball joint boot for removal. NOTE: It may be necessary to install a block of wood between the control arm and frame bracket to allow clearance for the ball joint press tool. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 8. Press the ball joint (4) from the upper control arm (3) using special tools C4212F (PRESS) (1), 97701 (Receiver) (2) and 97702 (Driver) (5). INSTALLATION NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Lower Ball Joint > Page 5942 1. Install the ball joint (3) into the upper control arm (4) and press in using special tools C4212F (press) (1), 9652 (Driver) (2) and 84451 (Receiver) (5). 2. Install the upper ball joint into the knuckle. 3. Install the upper ball joint retaining nut and tighten to 54 Nm (40 ft. lbs.). 4. Install the wheel speed sensor wire to the knuckle (HD) and to the upper control arm (LD). 5. Install the tire and wheel. 6. Remove the supports and lower the vehicle. 7. Perform a wheel alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application Control Arm Bushing: Customer Interest Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5952 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > Customer Interest for Control Arm Bushing: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5953 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application Control Arm Bushing: All Technical Service Bulletins Steering - Pulling/Shuddering Upon Brake Application NUMBER: 02-001-07 REV. A GROUP: Suspension DATE: March 31, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-001-07, DATED JANUARY 20, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE A CHANGE TO A LABOR OPERATION NUMBER. SUBJECT: When Braking The Vehicle May Drift To One Side Or Exhibits A Body Shudder OVERVIEW: This bulletin involves identifying the type of vehicle drift that may be present and implementing the appropriate repair procedures for the type of vehicle drift. MODELS: 2006 - 2007 (DR) Ram Truck (1500) NOTE: This bulletin applies to 4x2 and 4x4 light duty (1500 model) vehicles built on or before November 27, 2006 (MDH 1127XX). SYMPTOM/CONDITION: The customer when braking may experience a vehicle drift to one side and/or a vehicle body shudder. This condition may be more noticeable when brakes are applied at speeds of 88 km/h (55 mph). The vehicle body shudder may exhibit itself as: steering wheel shake, brake pedal pulsation, or seat or floor vibration. DIAGNOSIS: 1. Verify that all four (4) vehicle road tires are in good condition 2. Verify that the tire pressure in all four (4) vehicle road tires are set to 241 Kpa (35 psi). 3. Road test the vehicle in a safe environment on a flat and level road at a highway speed of approximately 88 km/h (55 mph). 4. Without applying the vehicle brakes. Does the vehicle exhibit a drift to the left, right, or both sides on a flat and level road? Record the direction of vehicle drift. a. If YES >>> then perform the section of the Repair Procedure for "Front Tire Cross-Switch and Front End Alignment.". b. If NO >>> then proceed to the next step. 5. Apply the vehicle brakes. On a flat and level road, does the vehicle exhibit a shudder or drift to the left, right, or both sides that is different than when the vehicle brakes are not applied? Evaluate the vehicle when braking several times (during deceleration, at the end of a stop, or during light, moderate, or hard stops). a. If YES >>> then perform the section of the Repair Procedure for "Front Lower Control Arm Bushings Replacement. b. If NO >>> then this bulletin does not apply. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5959 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: A. Front Tire Cross-Switch and Front End Alignment: 1. Cross-switch the front tire and wheel assemblies (left front to right front, and right front to left front). 2. With the front tire and wheel assemblies removed, inspect the front brakes for problems (i.e. grease, dragging brake pads, etc.) that may cause a drift condition. 3. Verify that the front suspension components are in good condition. 4. Align the vehicle front end to the following specifications: NOTE: Follow the above alignment specification. Pay particular attention to large differences in: left to right caster and left to right toe readings. 5. Road test the vehicle to verify that the condition has been corrected. B. Front Lower Control Arm Bushings Replacement: 1. Replace the left and right side front lower control arm bushings. Refer to TechCONNECT for detailed repair procedures: select the SERVICE INFO tab > 2 - SUSPENSION > FRONT > BUSHINGS > REMOVAL and INSTALLATION. NOTE: For the front lower control arm, the front (leading) bushing is different from the rear (trailing) bushing. Take care to install the correct bushing. 2. Verify that the front suspension components are in good condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm Bushing: > 02-001-07A > Mar > 07 > Steering - Pulling/Shuddering Upon Brake Application > Page 5960 3. Align the vehicle front end to the following specification: 4. Road test the vehicle to verify that the condition has been corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal Control Arm Bushing: Service and Repair Removal Lower Control Arm Bushings-4X2 (LD) LOWER CONTROL ARM BUSHINGS-4X2 (LD) REMOVAL 1. Remove the lower control arm. 2. Secure the control arm in a soft jaw vise. 3. Install the special tools onto the lower control arm (5) to press out the bushing (6) using C4212F (PRESS) (1), 97751 (receiver) (2), 97723 (driver) (4) and 97752 (SPACER) (3) Upper Control Arm Bushings-IFS (LD) UPPER CONTROL ARM BUSHINGS - IFS (LD) REMOVAL 1. Remove the upper control arm. 2. Secure the control arm in a soft jaw vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 3. Remove the bushing (3) from the upper control arm (5) using special tool C4212F (PRESS) (1), 97773 (receiver) (4), and 96011 (driver) (2). Upper Control Arm Bushings-IFS (HD) UPPER CONTROL ARM BUSHINGS-IFS (HD) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal > Page 5963 REMOVAL 1. Remove the upper control arm. 2. Secure the control arm in a soft jaw vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 3. Remove the bushing (3) from the upper control arm (5) using special tool C4212F (PRESS) (1), 97773 (receiver) (4), and 97772 (driver) (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal > Page 5964 Control Arm Bushing: Service and Repair Installation Lower Control Arm Bushings-4X2 (LD) LOWER CONTROL ARM BUSHINGS-4X2 (LD) INSTALLATION FRONT BUSHING 1. Install the bushing (3) using special tool C4212F (PRESS) (1), 97751 (receiver) (5), 97754 (driver) (2) and 97752 (SPACER) (4). REAR BUSHING 1. Install the bushing using special tool C4212F (PRESS) (1), 97751 (receiver) (2), 97753 (driver) (4) and 97752 (SPACER) (3). 1. Remove the control arm from the vise. 2. Install the lower control arm. 3. Perform a wheel alignment. Upper Control Arm Bushings-IFS (LD) UPPER CONTROL ARM BUSHINGS-IFS (LD) INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Removal > Page 5965 1. Install the bushing (3) into the control arm (5) using special tool C4212F (PRESS) (1), 97701 (receiver) (2) and 97712 (driver) (4). 2. Remove the control arm from the vise. 3. Install the upper control arm. 4. Perform a wheel alignment. Upper Control Arm Bushings - IFS (HD) UPPER CONTROL ARM BUSHINGS - IFS (HD) INSTALLATION 1. Install the bushing (3) into the control arm (5) using special tool C4212F (PRESS) (1), 97701 (receiver) (2) and 97771 (driver) (4). 2. Remove the control arm from the vise. 3. Install the upper control arm. 4. Perform a wheel alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair TRANSMISSION CROSSMEMBER REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (3-if equipped). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5970 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles-Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles-Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5971 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft.lbs.). 2. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft.lbs.). 4. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 5. Remove the transmission support (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 5972 6. Install the transfer case skid plate (3-if equipped). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation Front Steering Knuckle: Description and Operation KNUCKLE DESCRIPTION The knuckle (1) is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal Front Steering Knuckle: Service and Repair Removal (LD) 4X2 & 4X4 KNUCKLE REMOVAL (LD) 4X2 & 4X4 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 9360. 5. Remove the halfshaft nut (4X4 only). 6. Remove the upper ball joint nut. Separate the ball joint (4) from the knuckle (6) with Remover 9360 (5) CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5978 7. Remove the lower ball joint nut. Separate the ball joint from the knuckle with Remover 8677 (2). 8. Remove the steering knuckle (1) from the vehicle. 9. Remove the hub/bearing from the steering knuckle on the bench. (HD) 4X2 KNUCKLE REMOVAL (HD) 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper, rotor, shield and ABS wheel speed sensor if equipped. 4. Remove the tie rod end nut. Separate the tie rod from the knuckle with Remover 9360. 5. Remove the upper ball joint nut. Separate the ball joint from the knuckle with Remover 9360. CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the lower ball joint nut. Separate the ball joint from the knuckle with puller 8677 and remove the knuckle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5979 7. Remove the hub/bearing from the steering knuckle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5980 Front Steering Knuckle: Service and Repair Installation (LD) 4X2 & 4X4 KNUCKLE INSTALLATION (LD) 4X2 & 4X4 CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle (1) and tighten the bolts to 163 Nm (120 ft. lbs.). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts. Tighten the upper ball joint nut to 54 Nm (40 ft. lbs.) (an additional 90° turn is required) and the lower ball joint nut to 52 Nm (38 ft. lbs.)(an additional 90° turn is required). 4. Remove the hydraulic jack from the lower suspension arm (4). 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the front halfshaft into the hub/bearing (if equipped). 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) (if equipped). 8. Install the ABS wheel speed sensor (if equipped) and brake shield, rotor and caliper. 9. Install the wheel and tire assembly. 10. Remove the support and lower the vehicle. 11. Perform a wheel alignment. (HD) 4X2 KNUCKLE INSTALLATION (HD) 4X2 CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. NOTE: When installing hub/bearing with ABS brakes, position the speed sensor opening towards the front of the vehicle. 1. Install the hub/bearing to the steering knuckle and tighten the bolts to 176 Nm (130 ft. lbs.). 2. Install the knuckle onto the upper and lower ball joints. 3. Install the upper and lower ball joint nuts. Install and tighten the upper ball joint nut, to 54 Nm (40 ft. lbs.). Then Install and tighten the lower ball joint nut to 135 Nm (100 ft. lbs.). 4. Remove the hydraulic jack from the lower suspension arm. 5. Install the tie rod end and tighten the nut to 61 Nm (45 ft. lbs.). 6. Install the ABS wheel speed sensor if equipped and brake shield, rotor and caliper. 7. Install the wheel and tire assembly. 8. Remove the support and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Removal > Page 5981 9. Perform a wheel alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Removal Stabilizer Link: Service and Repair Removal STABILIZER LINK REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the lower nut. 3. Remove the upper nut, retainer and grommets. 4. Remove the stabilizer link (1) from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Removal > Page 5987 Stabilizer Link: Service and Repair Installation STABILIZER LINK INSTALLATION 4X2 1. Install the stabilizer link (1) to the vehicle. 2. Install the lower nut and Tighten to 102 Nm (75 ft. lbs.). 3. Install the retainers, grommets and upper nut and Tighten to 27 Nm (20 ft. lbs.). 4. Remove the support and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Description and Operation Suspension Spring ( Coil / Leaf ): Description and Operation SPRING DESCRIPTION ALL EXCEPT SRT10 - STANDARD CAB The rear suspension system uses a multileaf springs and a solid drive axle. The forward end of the springs are mounted to the body rail hangers through rubber bushings. The rearward end of the springs are attached to the body by the use of shackles. The spring and shackles use rubber bushings. OPERATION The springs control ride quality and maintain vehicle ride height. The shackles allow the springs to change their length as the vehicle moves over various road conditions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension Suspension Spring ( Coil / Leaf ): Service and Repair Front-Independent Front Suspension Removal SPRING REMOVAL 4X2 1. Raise and support vehicle. 2. Remove the front wheel and tire assembly. 3. Support the lower control arm (4) at the outboard side of the lower control arm to support vehicle weight. 4. Remove the shock absorber (5). 5. Install Spring Compressor DD1278 (3) up through the lower suspension arm, coil spring and shock hole in the frame. The bell-shaped adapter (3) goes against the lower suspension arm. Install the nut on top of the tool at the shock hole. 6. Tighten the spring compressor nut against bell-shaped adapter finger tight then loosen 1/2 turn. NOTE: This will hold the spring in place until the lower suspension arm is separated from the steering knuckle. 7. Remove the steering knuckle. 8. Remove the stabilizer link. 9. Remove the lower control arm support. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5993 10. Tighten the spring compressor tool (2) to collapse the coil spring. NOTE: It may necessary to loosen the control arm pivot bolt to allow downward swing. 11. Loosen the tension on the spring compressor tool (2) slowly allowing the lower suspension arm to pivot downward. 12. Remove the spring compressor tool (2). 13. Remove coil spring (1) and isolator pad from the vehicle. Installation SPRING INSTALLATION 4X2 1. Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well. 2. Install Spring Compressor DD1278 (2) up through the lower suspension arm, coil spring and shock hole in the frame. 3. Tighten the tool nut to compress the coil spring. 4. Install the steering knuckle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5994 5. Install the retaining nut on the upper ball joint and tighten to 54 Nm (40 ft. lbs.)(on 1500 series only an additional 90° turn is required) or 54 Nm (40 ft. lbs.)(HD 4X2 only). 6. Remove the spring compressor tool. 7. Support the lower control arm at the outboard side of the lower control arm to support vehicle weight. 8. Install the shock absorber. 9. Install the stabilizer link. 10. Remove the lower control arm support. 11. Install the wheel and tire assembly and lower the vehicle. 12. Lower the vehicle to the floor with vehicle weight and Tighten the front and rear control arm frame pivot bolts if loosened to 204 Nm (150 ft. lbs.) for (LD) or 285 Nm (210 ft. lbs.)for (HD). 13. Perform a wheel alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5995 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing BUSHINGS REMOVAL NOTE: When removing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Remove the spring from the vehicle. 2. Make small relief cuts in the flared up end of the bushing metal being careful not to cut the spring. Use a punch to bend the flared bushing metal down for push out. 3. Position the spring eye in a press. 4. Press the bushing out with an appropriate size driver. INSTALLATION NOTE: When installing the LD front eye bushing be sure to note the orientation of the "voids" or holes. The voids need to be in line with the main leaf when installing the new bushing or vehicle ride will degrade. 1. Press new bushing into the spring eye with an appropriate size driver. The bushing should be centered in the spring eye. 2. Stake the outermetal of the bushing in a minimum of six points to retain the bushing. 3. Install the spring on the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5996 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Spring Tip Inserts SPRING TIP INSERTS REMOVAL 1. Raise and support the vehicle. 2. Remove both rear tire and wheel assemblies. 3. Position a large C-Clamp (3) adjacent to the spring clinch clip (1) and clamp the leaves of the spring together CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury. 4. Use an appropriate pry bar (2) to bend open the spring clinch clip (1). If necessary, remove the existing spring clinch clip isolators. 5. Use the pry bar (2) to spread apart the leaf (1). The clearance between the leaves should be enough to remove the old liner (if necessary) and install the replacement liner. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5997 6. If necessary, remove the old spring tip liner (1). INSTALLATION 1. With the prybar still inserted between the leaves, install a new spring tip liner onto the leaf. 2. Firmly seat the spring tip liner onto the leaf. A C-Clamp (1) can be used to compress the adjacent leaves together which will seat the liner retaining pin into the hole. NOTE: The spring tip liner is properly installed when the retaining pin is pointing toward the pavement and the wear pad is contacting the leaf spring. 3. Apply a small amount of lubricant oil onto the tip liner wear pad. 4. Install all the spring tip liners. 5. Place one spring clinch clip isolator (1) onto the outboard side of the spring clinch clip and one isolator on the inboard side of the spring clinch clip. 6. Using large adjustable pliers (2), close the spring clinch clip (1) until the isolator contacts the leaf spring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5998 CAUTION: Do not use a hammer to close the spring clinch clip. Damage to the isolator may result. 7. Use an appropriate pry bar to bend open the spring clinch clip. If necessary, remove the existing spring clinch clip isolators. 8. Repeat procedure for the other side of the vehicle. 9. Install the tire wheel assemblies. 10. Lower the vehicle. Spring-All Except SRT10 - Standard Cab SPRING REMOVAL ALL EXCEPT SRT10 - STANDARD CAB 1. Raise and support the vehicle. 2. Support the axle with a suitable holding fixture. 3. Remove the nuts, spring clamp bolts (5) and the plate that attach the spring (1) to the axle. 4. Remove the nuts and bolts from the spring front and rear shackle (6). 5. Remove the spring (1) from the vehicle. INSTALLATION 1. Position spring (1) on axle shaft tube so spring center bolt is inserted into the locating hole in the axle tube. 2. Align the front of the spring with the bolt hole in the front bracket. Install the eye pivot bolt and nut (4). 3. Align the rear of the spring into the shackle (6) and install the bolt and nut. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front-Independent Front Suspension > Page 5999 4. Tighten the spring front and rear eye pivot bolt snug, Do not torque. 5. Install the spring clamp bolts (5), plate (2) and the retaining nuts (3). 6. Remove the holding fixture for the rear axle. 7. Remove the supports and lower the vehicle so that the weight is being supported by the tires. 8. Tighten the spring clamp retaining nuts (3) to 149 Nm (110 ft. lbs.). 9. Tighten the spring front and rear pivot bolt nuts to 163 Nm (120 ft. lbs.) (LD) or 230 Nm (170 ft. lbs.) (HD). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection Suspension Strut / Shock Absorber: Testing and Inspection SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil base lubricants will deteriorate the bushing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension Suspension Strut / Shock Absorber: Service and Repair Front-Independent Front Suspension Removal SHOCK REMOVAL 4X2 1. Raise and support vehicle. 2. Support the lower control arm outboard end. 3. Remove the upper shock absorber nut using wrench 9362 (1), retainer and grommet (2). 4. Remove the lower bolts and remove the shock absorber. Installation SHOCK INSTALLATION 4X2 NOTE: Upper shock nut must be replaced or use Mopar Lock 'N Seal or Loctite 242 on existing nut. 1. Install the lower retainer and grommet on the shock absorber stud. Insert the shock absorber through the frame bracket hole. 2. Install the lower bolts and tighten the bolts to 35 Nm (25 ft. lbs.). 3. Install the upper grommet, retainer (2) and new nut or use Mopar Lock 'N Seal or Loctite 242 on existing nut, on the shock absorber stud. Tighten nut to 54 Nm (40 ft. lbs.). using wrench 9362 (1). 4. Remove the support from the lower control arm outboard end. 5. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front-Independent Front Suspension > Page 6005 Suspension Strut / Shock Absorber: Service and Repair Rear SHOCK REMOVAL 1. Raise vehicle and support the axle. NOTE: The rear upper shock attachment uses a flag nut. Do not use an air tool to remove the bolt, the flag may rotate into the bottom of the bed and cause damage. Use a wrench to hold the nut when loosening. 2. Remove the upper shock bolt and nut (1). 3. Remove the lower shock bolt and nut. 4. Remove the rear shock absorber (3) from the vehicle. INSTALLATION 1. Position the shock absorber (3) in the brackets. 2. Install the bolts through the brackets and the shock. Install the flag nut (1) on the top bolt and nut on lower bolt. 3. Tighten the upper and lower bolt/nuts. Tighten to 135 Nm (100 ft. lbs.) 4. Remove the support and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair Suspension Travel Bumper: Service and Repair JOUNCE BUMPER REMOVAL 1. Remove the two bolts (1) securing the jounce bumper (2) to the bracket. 2. Remove the jounce bumper (2). INSTALLATION 1. Install the jounce bumper (2). 2. Install the two bolts (1) securing the jounce bumper (2) to the bracket. Tighten the bolts to 40 Nm (30 ft. lbs.) (LD) or Tighten the bolts to 61 Nm (45 ft. lbs.) (HD). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6021 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6022 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6023 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6024 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6025 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6026 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6027 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6037 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6038 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6039 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6040 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6041 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6042 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6043 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6044 Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Removal Wheel Bearing: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Removal > Page 6047 Wheel Bearing: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6060 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6061 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6062 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6063 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6064 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6065 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6066 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6076 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6077 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6078 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6079 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6080 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6081 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6082 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Removal Wheel Hub: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Service and Repair > Removal > Page 6085 Wheel Hub: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6094 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6095 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6096 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6097 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6098 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6099 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6100 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6106 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6107 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6108 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6109 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6110 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6111 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6112 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair Standard Procedure Refer to the Owner's Manual for emergency vehicle lifting procedures. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 6117 WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACK Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 6118 When properly positioned, a floor jack can be used to lift a vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. CAUTION: Do not lift vehicle with a floor jack positioned under: An axle tube. A body side sill. A steering linkage component. A drive shaft. The engine or transmission oil pan. The fuel tank. A front suspension arm. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 6119 NOTE: Use the correct front frame rail lifting locations only. NOTE: Use the correct rear frame rail lifting locations only. HOIST Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 6120 A vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist. NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 6121 NOTE: The forward lifting pads should be positioned against the forward flange of the transmission crossmember brackets at the bottom of the frame rail. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair > Page 6122 NOTE: The rear lifting pads should be wedged between the forward flange of the leaf spring bracket and the frame rail. Safety stands should be placed under the frame rails at the front and rear ends. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position, the SKREEM sends a TPM lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Lamp-On Message - Each time the cluster receives a TPM lamp-on message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a TPM lamp-off message from the SKREEM or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid TPM lamp-on or lamp-off message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the On position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper TPM lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is inoperative. For proper diagnosis of the SKREEM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the TPM indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information > Description and Operation Spare Tire: Description and Operation DESCRIPTION SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M.P.H. when using the temporary spare tire. Refer to Owner's Manual for complete details. FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Refer to Owner's Manual for complete details. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 6135 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6136 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6137 Wheels: Description and Operation WHEELS DESCRIPTION Original equipment wheels are designed for the specified Maximum Vehicle Capacity. All models use steel or aluminum drop center wheels. Aluminum wheels require special balance weights and alignment equipment. 1. On vehicles equipped with dual rear wheels, The rim is an eight stud hole pattern wheel. The wheels have a flat mounting surface (1). 2. The slots (1) in the wheel must be aligned to provide access to the valve stem. WHEEL DESIGN The rim size is on the vehicle safety certification label located on the drivers door shut face. The size of the rim is determined by the drivetrain package. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6138 wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6139 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6152 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6153 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6154 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6155 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6156 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6157 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Recalls for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6158 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Bearing: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6168 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6169 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6170 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6171 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6172 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6173 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Bearing: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6174 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Page 6175 Wheel Bearing: Specifications Wheel Bearing Grease ...................................................................................................... Mopar Multi-Purpose Lubricant NLGI Grade 2 EP, GC-LB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal Wheel Bearing: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Removal > Page 6178 Wheel Bearing: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Service and Repair Wheel Cover: Service and Repair WHEEL COVER REMOVAL NOTE: The hub caps must be removed before raising the vehicle off the ground. NOTE: You must use the flat end of the hub/cap remover/installer combination tool to pry off the wheel skins. Insert the flat tip completely and using a back and forth motion, loosen the wheel skin. repeat this procedure around the tire until the wheel skin pops off. 1. On 2500/3500 single rear wheel (SRW) models, insert a hub/cap remover/installer combination tool using the blade on the end of the tool to pry the cap off in a back and forth motion. 2. On 3500 models with Dual Rear Wheels (DRW), you must first remove the hub caps. The hub/cap remover/installer combination tool must be inserted in the pry off notch of the rear hub caps. 3. Position the hub/cap remover/installer combination tool and pull out on the tool firmly. The cap should come off. 4. The wheel skins can now be removed from the wheel. 5. On 3500 models front hub caps use the hub/cap remover/installer combination tool to pry off the cap in a back and forth motion. The wheel skins can now be removed. INSTALLATION REAR 1. Install one 1 1/2 inch valve stem extension on each rear inner wheel. NOTE: A 3/8 inch drive 10mm deep wheel socket with a 10 inch or greater extension can be used to remove the existing valve stem cap and install the extension. 2. Install one 1 inch valve stem extension on each outer wheel. 3. Align the cooling windows of the wheel skin with the cooling windows of the wheel. Seat one side of the wheel skin's retainer onto the wheel. Using a rubber mallet, strike the wheel skin on the outer circumference. Strike at several locations around the circumference until the skin is fully seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub/cap wheel skin to ensure that they are properly installed. FRONT 1. Align the valve stem with the notch in the wheel skin. 2. Seat on side of the wheel skin's wire retainer on to the wheel. 3. Using a rubber mallet, strike the opposite side of the wheel skin until the skin is properly seated. NOTE: The wheel skin and the hub cap are fully seated when there is a consistent gap between the skin/cap and the wheel. 4. Tug on the hub cap/wheel skin to ensure that they are properly installed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: Recalls Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6194 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6195 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6196 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6197 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6198 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6199 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Recalls for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6200 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > NHTSA07V038000 > Feb > 07 > Recall 07V038000: Front Hub/Bearing Replacement Wheel Hub: All Technical Service Bulletins Recall 07V038000: Front Hub/Bearing Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V038000 MFG'S REPORT DATE: February 06, 2007 COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED: 86333 SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control and cause a crash without warning. REMEDY: Dealers will replace the front hub and bearing units. The recall is expected to begin during February 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. G02. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6210 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6211 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6212 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6213 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6214 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6215 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6216 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Removal Wheel Hub: Service and Repair Removal HUB / BEARING REMOVAL 4X2 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly 3. Remove the brake caliper and rotor. 4. Remove the ABS wheel speed sensor if equipped (4). 5. Remove the three hub/bearing mounting bolts (5) from the steering knuckle (3). 6. Slide the hub/bearing (1) out of the steering knuckle (3). NOTE: The next step excludes SRT10. (SRT10 does not have a dust shield) 7. Remove the brake dust shield (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Service and Repair > Removal > Page 6219 Wheel Hub: Service and Repair Installation HUB / BEARING INSTALLATION 4X2 1. Install the brake dust shield (2). SRT10 Excluded in this step. 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.) 4X2 LD. Or tighten the bolts (5) to 176 Nm (130 ft. lbs.) 4X2 HD.. 3. Install the brake rotor and caliper. 4. Install the ABS wheel speed sensor if equipped (4). 5. Install the wheel and tire assembly. 6. Remove the support and lower vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6228 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6229 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6230 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6231 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6232 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6233 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > Recalls for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6234 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement Technical Service Bulletin # G02 Date: 070201 Recall - Front Hub/Wheel Bearing Replacement February 2007 Dealer Service Instructions for: Safety Recall G02 Front Wheel Bearing and Hub Assembly Models 2006 (DR) Dodge Ram 1500 Series Pick Up Truck NOTE: This recall applies only to the above vehicles built from November 9, 2005 through April 27, 2006 (MDH 110900 through 042700). 1500 series Mega-Cab pick up trucks are not included in this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front wheel bearings on about 85,000 of the above vehicles may have been manufactured with an insufficient amount of grease and could fail. This can lead to wheel separation and result in a crash without prior warning. Repair The right and left side front wheel bearing and hub assemblies must be inspected. Wheel bearings within the suspect build date range must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6240 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6241 Use the labor operation numbers and time allowances shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6242 If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure A. Inspect Hub and Bearing Date Code 1. Raise the vehicle on an appropriate hoist. 2. Remove the front wheel and tire assemblies. 3. Remove the brake caliper adapter bolts and then remove the adapter and brake caliper as an assembly on both sides (Figure 1). CAUTION: Never allow the disc brake caliper and adapter to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper assembly securely. 4. Remove both front brake rotors from the bearing hubs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6243 5. Inspect the 5 digit date code on both front wheel hubs. The date code is located on the outside edge of the wheel hub flange (Figure 2). > If the date range on the hub is 05306 through 06074, or is unreadable, replace the hub and bearing assembly. Continue to Section B Hub and Bearing Replacement. NOTE: The hub may have additional numbers stamped on the outside edge. The date code is a 5 digit number. > If the date range is 05305 or lower, OR 06075 or higher, the bearing and hub assembly is good. Continue to Section C. Assemble After Bearing and Hub Inspection or Replacement. B. Hub and Bearing Replacement Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6244 1. For speed sensor equipped vehicles, disconnect the wheel speed sensor(s) wire at the fender splash shield and upper control arm (Figure 3). CAUTION: Note the speed sensor wire routing to ensure that the new sensor wire is routed the same way. 2. For 4x4 equipped vehicles, remove the halfshaft nut. 3. Remove the three hub/bearing mounting bolts from the steering knuckle (Figure 4). NOTE: On 4x4 equipped vehicles, push the halfshaft inward to gain access to the bearing retaining bolts (Figure 4). Alternately loosen the bolts a few turns at a time until the bolts are fully disengaged from the bearing hub flange. 4. Slide the hub/bearing out of the steering knuckle and discard (Figure 3). 5. Clean any debris from the front bearing hub knuckle bore. 6. With the brake dust shield in position, install the new hub/bearing into the steering knuckle and tighten the bolts to 120 ft. lbs. (163 N.m) (Figure 3). 7. For 4x4 equipped vehicles, install the halfshaft nut and tighten to 185 ft. lbs. (251 N.m). 8. For speed sensor equipped vehicles, route the wheel speed sensor wire along its original routing location and connect the sensor to the body wiring harness. 9. Continue with Section C. Assemble After Bearing and Hub Inspection or Replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6245 C. Assemble After Bearing and Hub Inspection or Replacement 1. Install the front brake rotors onto the bearing hubs. 2. Install the front brake calipers and adapters. Tighten the brake caliper adapter mounting bolts to 130 ft. lbs. (175 N.m). 3. Install the wheel and tire assemblies. Tighten the lug nuts to 130 ft. lbs. (176 N.m) in the sequence shown in Figure 5. 4. Lower the vehicle from the hoist. CAUTION: Pump the brake pedal several times to remove any clearance between the brake pads and rotor before attempting to move the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub (Locking) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub (Locking): > G02 > Feb > 07 > Recall - Front Hub/Wheel Bearing Replacement > Page 6246 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS 1500 Series Lug Nut 9/16 X 18 with 60° Cone LD .............................................................................................................................. 183 Nm (135 ft. lbs.) 2500 Series Lug Nut 9/16 X 18 with 60° Cone HD SRW .................................................................................................................... 197 Nm (145 ft. lbs.) 3500 Series Lug Nut 9/16 X 18 with Flat Washer HD DRW ............................................................................................................... 210 Nm (155 ft. lbs.) 8-lug. (SRT-10). 6-bolt pattern. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6250 Wheel Fastener: Service and Repair STUDS REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using special tool C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). INSTALLATION 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Page 6251 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation Accumulator HVAC: Description and Operation The A/C accumulator (5) is mounted in the engine compartment between the evaporator outlet tube (2) and the A/C suction line (6). An integral mounting bracket (4) is used to secure the accumulator to the dash panel (3). The A/C low side service port (1) is mounted to the top of the A/C accumulator. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The A/C accumulator has no serviceable parts except for the rubber O-ring seals, low side service port valve, cap and secondary retaining clips. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C accumulator is removed and installed. The A/C accumulator cannot be repaired and, if faulty or damaged, it must be replaced. Refrigerant enters the A/C accumulator (1) mostly as a low pressure vapor through the inlet tube (2). Any liquid, oil-laden refrigerant falls to the bottom of the canister, which acts as a separator. A desiccant bag (3) is mounted inside the accumulator canister to absorb any moisture which may have entered and become trapped within the refrigerant system. A filter (4) is also mounted inside the canister to trap any foreign material that may have entered the refrigerant system during assembly. The low pressure vapor exits the A/C accumulator through the outlet tube (5). On this model, the low side service port (6) is located at the top of the A/C accumulator. The A/C accumulator cannot be repaired. If the A/C accumulator is faulty or damaged, or if the A/C compressor has failed, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 6256 Accumulator HVAC: Service and Repair REMOVAL WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF BEFORE PERFORMING THE FOLLOWING OPERATION. 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system. 3. Remove the air filter housing cover to gain access to the A/C accumulator (9). 4. Remove the secondary retaining clip (11) from the spring-lock coupler (1) that secures the A/C suction line (10) to the accumulator outlet tube (2). 5. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 6. If equipped, disengage the push-pin type wire harness retainer from the plastic wire harness bracket located on the side of the A/C accumulator and position the engine wire harness out of the way. 7. Loosen the bolts (8) that secure the A/C accumulator to the bracket (7) located on the dash panel. 8. Remove the secondary retaining clip (4) from the spring-lock coupler (6) that secures the accumulator inlet tube (3) to the evaporator outlet tube (5). 9. Using the proper A/C line disconnect tool, disconnect the accumulator inlet tube from the evaporator outlet tube and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened refrigerant system connections. 11. If the A/C accumulator is being replaced, remove the accumulator mounting bolts and the plastic wire harness bracket (if equipped) from the accumulator. INSTALLATION NOTE: If the A/C accumulator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Description and Operation > Page 6257 1. If the A/C accumulator (9) is being replaced, loosely install the accumulator mounting bolts (8) and the plastic wire harness bracket (if equipped) on to the accumulator. 2. Position the A/C accumulator onto the bracket located on the dash panel (7) in the engine compartment. Do not tighten the accumulator mounting bolts at this time. 3. Remove the tape or plugs from the opened refrigerant system connections. 4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fittings (1 and 6). Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Connect the spring-lock coupler that secures the accumulator inlet tube (3) to the evaporator outlet tube (5) and install the secondary retaining clip (4). 6. Tighten the accumulator mounting bolts to 4.5 N.m (40 in. lbs.). 7. If equipped, engage the engine wire harness retaining clip to the plastic wire harness bracket located on the side of the A/C accumulator. 8. Connect the A/C suction line (10) to the accumulator outlet tube (2) and install the secondary retaining clip (11). 9. Install the air filter housing cover. 10. Evacuate the refrigerant system. 11. Charge the refrigerant system. 12. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-021-04 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heat Duct Air Door Actuator / Motor: Customer Interest A/C - Lack of Air Flow From Rear Seat Heat Duct NUMBER: 24-021-04 GROUP: Heating & A/C DATE: Dec. 16, 2005 SUBJECT: Mega Cab - Lack Of Air Flow From Rear Seat Heat Duct OVERVIEW: This bulletin involves replacing the rear seat heat duct actuator lever. MODELS: 2006 DR Ram Truck Mega Cab NOTE: This bulletin applies to 2006 Ram Truck Mega Cab built between 08/29/2005 and 08/31/2005 (MDH - 0829XX & 0831XX). SYMPTOM/CONDITION: The rear seat actuator rod could become disconnected from the actuator lever, causing the rear seat heater door to become inoperative. DIAGNOSIS: Inspect the rear seat heater actuator rod. If the rod is disconnected from the actuator lever, perform the Repair Procedure. The actuator can be viewed from the passenger side foot well (Fig. 1). PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in the 2006 Ram Truck Service Information on TechCONNECT, lower the steering column and instrument panel to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-021-04 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heat Duct > Page 6267 gain access to the Heater A/C assembly. It is not necessary to completely remove the instrument panel 2. Remove the mode (defrost) actuator (Fig. 1). 3. Remove the white plastic rear seat heat duct lever from the mode actuator and discard it. 4. Install the new lever, p/n 05189140AA, onto the actuator (Fig. 1). 5. Install the mode actuator on to the heater NC assembly 6. Install the instrument pane and steering column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-021-05 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heater Duct Air Door Actuator / Motor: Customer Interest A/C - Lack of Air Flow From Rear Seat Heater Duct NUMBER: 24-021-05 GROUP: Heating & A/C DATE: Dec. 16, 2005 SUBJECT: Mega Cab - Lack Of Air Flow From Rear Seat Heat Duct OVERVIEW: This bulletin involves replacing the rear seat heat duct actuator lever. MODELS: 2006 DR Ram Truck Mega Cab NOTE: This bulletin applies to 2006 Ram Truck Mega Cab built between 08/29/2005 and 08/31/2005 (MDH - 0829XX & 0831XX). SYMPTOM/CONDITION: The rear seat actuator rod could become disconnected from the actuator lever, causing the rear seat heater door to become inoperative. DIAGNOSIS: Inspect the rear seat heater actuator rod. If the rod is disconnected from the actuator lever, perform the Repair Procedure. The actuator can be viewed from the passenger side foot well (Fig. 1). PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in the 2006 Ram Truck Service Information on TechCONNECT, lower the steering column and instrument panel to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 24-021-05 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heater Duct > Page 6272 gain access to the Heater A/C assembly. It is not necessary to completely remove the instrument panel 2. Remove the mode (defrost) actuator (Fig. 1). 3. Remove the white plastic rear seat heat duct lever from the mode actuator and discard it. 4. Install the new lever, p/n 05189140AA, onto the actuator (Fig. 1). 5. Install the mode actuator on to the heater A/C assembly 6. Install the instrument pane and steering column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-021-04 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heat Duct Air Door Actuator / Motor: All Technical Service Bulletins A/C - Lack of Air Flow From Rear Seat Heat Duct NUMBER: 24-021-04 GROUP: Heating & A/C DATE: Dec. 16, 2005 SUBJECT: Mega Cab - Lack Of Air Flow From Rear Seat Heat Duct OVERVIEW: This bulletin involves replacing the rear seat heat duct actuator lever. MODELS: 2006 DR Ram Truck Mega Cab NOTE: This bulletin applies to 2006 Ram Truck Mega Cab built between 08/29/2005 and 08/31/2005 (MDH - 0829XX & 0831XX). SYMPTOM/CONDITION: The rear seat actuator rod could become disconnected from the actuator lever, causing the rear seat heater door to become inoperative. DIAGNOSIS: Inspect the rear seat heater actuator rod. If the rod is disconnected from the actuator lever, perform the Repair Procedure. The actuator can be viewed from the passenger side foot well (Fig. 1). PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in the 2006 Ram Truck Service Information on TechCONNECT, lower the steering column and instrument panel to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-021-04 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heat Duct > Page 6278 gain access to the Heater A/C assembly. It is not necessary to completely remove the instrument panel 2. Remove the mode (defrost) actuator (Fig. 1). 3. Remove the white plastic rear seat heat duct lever from the mode actuator and discard it. 4. Install the new lever, p/n 05189140AA, onto the actuator (Fig. 1). 5. Install the mode actuator on to the heater NC assembly 6. Install the instrument pane and steering column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-021-05 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heater Duct Air Door Actuator / Motor: All Technical Service Bulletins A/C - Lack of Air Flow From Rear Seat Heater Duct NUMBER: 24-021-05 GROUP: Heating & A/C DATE: Dec. 16, 2005 SUBJECT: Mega Cab - Lack Of Air Flow From Rear Seat Heat Duct OVERVIEW: This bulletin involves replacing the rear seat heat duct actuator lever. MODELS: 2006 DR Ram Truck Mega Cab NOTE: This bulletin applies to 2006 Ram Truck Mega Cab built between 08/29/2005 and 08/31/2005 (MDH - 0829XX & 0831XX). SYMPTOM/CONDITION: The rear seat actuator rod could become disconnected from the actuator lever, causing the rear seat heater door to become inoperative. DIAGNOSIS: Inspect the rear seat heater actuator rod. If the rod is disconnected from the actuator lever, perform the Repair Procedure. The actuator can be viewed from the passenger side foot well (Fig. 1). PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in the 2006 Ram Truck Service Information on TechCONNECT, lower the steering column and instrument panel to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 24-021-05 > Dec > 05 > A/C - Lack of Air Flow From Rear Seat Heater Duct > Page 6283 gain access to the Heater A/C assembly. It is not necessary to completely remove the instrument panel 2. Remove the mode (defrost) actuator (Fig. 1). 3. Remove the white plastic rear seat heat duct lever from the mode actuator and discard it. 4. Install the new lever, p/n 05189140AA, onto the actuator (Fig. 1). 5. Install the mode actuator on to the heater A/C assembly 6. Install the instrument pane and steering column. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 6284 HVAC Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 6285 Air Door Actuator / Motor: Diagrams Actuator - Blend Door (Single Zone) Actuator - Blend Door - Driver (Dual Zone) Actuator - Blend Door - Passenger (Dual Zone) Actuator - Blend Door 1 (Panel To Floor) Actuator - Mode Door 2 (Defrost To Floor) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 6286 Actuator - Recirculation Door Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door Air Door Actuator / Motor: Description and Operation Actuator-Blend Door The blend door actuators are reversible, 12-volt direct current (DC), servo motors. Models with the single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models with the dual zone system have two blend-air doors, which are controlled by two blend door actuators. The blend door actuator (1) for the single zone heating- A/C system is located near the center of the HVAC housing (2), close to the dash panel. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, which is mechanically connected to only the driver side blend air door. A second separate blend door actuator (3) located on the top of the HVAC housing is mechanically connected to the passenger side blend-air door. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connect it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The blend door actuators do not require mechanical indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control. The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 6289 When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a scan tool. The blend door actuators cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 6290 Air Door Actuator / Motor: Description and Operation Actuator-Mode Door The mode door actuators are reversible, 12-volt direct current (DC) servo motors. The heating-A/C systems on this vehicle use two mode door actuators. One for the panel/floor-air door and one for the defrost-air door. Both the panel/floor door actuator (1) and the defrost door actuator (2) are located on the driver side end of the HVAC housing (3), close to the dash panel. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The mode door actuators do not require mechanical indexing to the mode- air doors, as they are electronically calibrated by the A/C-heater control. The mode door actuators are connected to the A/C-heater control through the vehicle electrical system by dedicated two-wire leads and connectors of the HVAC wire harness. The mode door actuators can move the defrost-air door and the panel/floor-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the mode door actuators and the mode-air doors. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuators are diagnosed using using a scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 6291 The mode door actuators cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Actuator-Blend Door > Page 6292 Air Door Actuator / Motor: Description and Operation Actuator-Recirculation Door The recirculation door actuator (1) is a reversible 12-volt direct current (DC) servo motor. The single recirculation door actuator is located on the passenger side end of the HVAC housing (2), on the top of the air inlet housing. All actuators (1) are interchangeable with each other. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle (2). Each actuator also has an identical output shaft with splines (3) that connects it to its respective door linkage and three integral mounting tabs (4) that allow the actuator to be secured to the HVAC housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. The recirculation door actuator is connected to the heater-A/C control module through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator is diagnosed using a scan tool. The recirculation door actuator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door Air Door Actuator / Motor: Service and Repair Actuator-Blend Door NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE DRIVER SIDE REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle 3. Remove the two screws (1) that secure the blend door actuator (2) to the back of the HVAC housing (3). 4. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the blend door actuator from the vehicle. INSTALLATION 1. Install the blend door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend door lever (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6295 2. Install the screws (1) that secure the blend door actuator (2) to the HVAC housing (3). Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the blend door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. DUAL ZONE PASSENGER SIDE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the blend door lever (1) from the blend door actuator output shaft (2) and the blend door linkage (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6296 4. Remove the two screws (1) that secure the blend door actuator and bracket assembly (2) to the top of the HVAC housing (3). 5. Remove the blend door actuator and bracket assembly from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 6. Remove the blend door actuator and bracket assembly from the vehicle. INSTALLATION 1. Install the blend door actuator and bracket assembly (2) onto the top of the HVAC housing (3). 2. Install the screws (1) that secure the blend door actuator and bracket assembly to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the blend door actuator. NOTE: Align the guide pin on the blend door lever with the guides on the blend door linkage during Installation of the blend door lever. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6297 4. Install the blend door lever (1) onto the blend door actuator output shaft (2) and the blend door linkage (3). 5. Install the instrument panel. 6. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6298 Air Door Actuator / Motor: Service and Repair Actuator-Mode Door WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heating-A/C system is equipped with two mode door actuators, one for the panel/floor-air door and one for the defrost-air door. PANEL/FLOOR DOOR ACTUATOR REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the screws (1) that secure the panel/floor door actuator (2) to the back of the HVAC housing (3). 4. Remove the panel/floor door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the panel/floor door actuator from the vehicle. INSTALLATION 1. Install the panel/floor door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the panel/floor door actuator coupler (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6299 2. Install the screws (1) that secure the panel/floor door actuator (2) to the HVAC housing (3). Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the panel/floor door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. DEFROST DOOR ACTUATOR REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. 3. Remove the screws (1) that secure the defrost door actuator (2) to the back of the HVAC housing (3). 4. Remove the defrost door actuator from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the defrost door actuator from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6300 1. Install the defrost door actuator (1) onto the back of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the defrost door actuator coupler (4). 2. Install the screws (1) that secure the defrost door actuator (2) to the HVAC housing (3). Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the defrost door actuator. 4. Install the instrument panel. 5. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6301 Air Door Actuator / Motor: Service and Repair Actuator-Recirculation Door REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Remove the two screws (1) that secure the recirculation door actuator (2) to the side of the HVAC air inlet housing (3). 4. Remove the recirculation door actuator from the air inlet housing and disconnect the HVAC wire harness connector (4) from the actuator. 5. Remove the recirculation door actuator from the vehicle. INSTALLATION 1. Install the recirculation door actuator (1) onto the side of the HVAC air inlet housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those in the recirculation door actuator coupler (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Actuator-Blend Door > Page 6302 2. Install the two screws (1) that secure the recirculation door actuator (2) to the air inlet housing (3). Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the HVAC wire harness connector (4) to the recirculation door actuator. 4. Install the glove box. 5. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation Air Duct: Description and Operation There are four defroster air outlets (1) in the defroster grille (2) located on the top of the instrument panel (3). The airflow from the defroster outlets is directed by fixed vanes in the defroster grille and cannot be adjusted. The defroster air outlets are not serviceable from the defroster grille. There are two side window demister air outlets (4). One located on each end of the instrument panel near the A-pillar area. The airflow from the side window demister air outlets is directed by fixed vanes in the outlets and cannot be adjusted. The driver side window demister air outlet is serviced with the instrument cluster bezel and the passenger side demister outlet is serviced with the instrument panel cover. There are four instrument panel air outlets (5). One air outlet is located near the end of the instrument panel facing the rear of the vehicle and two outlets are located on the instrument panel center bezel. Each of the instrument panel air outlets contain a grille with movable vanes that are used to direct or shut off the flow of the conditioned air leaving the instrument panel outlets. The driver side instrument panel air outlet is serviced with the instrument cluster bezel, the passenger side instrument panel air outlet is serviced with the instrument panel cover and the two center air outlets are serviced with the center bezel. On Mega Cab models there are two outlets located at the rear of the center front seat. Each of the rear air outlets contain a grille with movable vanes that are used to direct or shut off the flow of the conditioned air leaving the outlets. The rear air outlets are not serviceable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console Air Duct: Service and Repair Duct-Floor Console REMOVAL NOTE: Illustration shown with seat cushions removed for clarity. 1. Remove the floor console. 2. Disengage the floor console duct (1) from the rear duct adapter (3) located at the front of the rear duct (2) below the center front seat and slide the adapter rearward into the rear duct. 3. Disengage the floor console duct from the floor distribution duct (4) located on the bottom of the HVAC housing (5) and remove the console duct from the vehicle. NOTE: Illustration shown with center front seat removed for clarity. 4. If required, remove the front seat and remove the three push-pin retainers (1) that secure the rear duct (2) to the bottom of the center seat support (3). 5. Disengage the rear duct from the rear outlet (4) and remove the rear duct. INSTALLATION NOTE: Illustration shown with center front seat removed for clarity. 1. If removed, install the rear duct (2) onto the rear outlet (4). Make sure the duct is fully engaged to the outlet. 2. Install the three push-pin retainers (1) that secure the rear duct to the front seat support (3) and install the front seat. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6308 NOTE: Illustration shown with seat cushions removed for clarity. 3. Install the floor console duct (1) onto the floor distribution duct (4) located at the bottom of the HVAC housing (5). Make sure the ducts are fully engaged to each other. 4. Slide the rear duct adapter (3) forward and install the floor console duct onto the rear duct (2). Make sure the ducts are fully engaged to each other. 5. Install the floor console. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6309 Air Duct: Service and Repair Duct-Defroster REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. If required, disconnect the center radio speaker wire harness connector (1) and position it the wire harness lead out of the way. 3. Remove the screw (4) that secures the defroster duct adapter (3) to the instrument panel support. 4. Remove the defroster duct adapter from the defroster duct (5). 5. Remove the six screws (2) that secure the defroster duct to the instrument panel. 6. Remove the defroster duct from the instrument panel. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6310 1. Position the defroster duct (5) into the instrument panel. 2. Install the six screws (2) that secure the defroster duct to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the defroster duct adapter (3) onto the defroster duct. 4. Install the screw (4) that secures the defroster duct adapter to the instrument panel support. Tighten the screw to 2.2 N.m (20 in. lbs.). 5. If removed, connect the center radio speaker wire harness connector (1) to the speaker. 6. Install the instrument panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6311 Air Duct: Service and Repair Duct-Floor Distribution NOTE: Regular Cab model shown. Other models similar. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the HVAC housing from the vehicle. 2. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 3. Remove the floor distribution duct from the HVAC housing. INSTALLATION 1. Position the floor distribution duct (1) onto the bottom of the HVAC housing (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6312 2. Install the screws (3) that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6313 Air Duct: Service and Repair Duct-Instrument Panel REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the radio. 3. Remove the defroster duct. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support (3) and remove the duct. 5. Disconnect the right side instrument panel duct adapter (2) from the right side instrument panel duct (1) and remove the adapter. 6. Remove the screw that secures each intermediate demister duct (3 and 4) to the instrument panel cover. 7. Disconnect the intermediate demister ducts from the demister ducts and remove the intermediate ducts. 8. Disconnect the left side instrument panel duct adapter (6) from the right side instrument panel duct (5) and remove the adapter 9. Remove the instrument panel cover. 10. Remove the three screws that secure each instrument panel duct to the instrument panel support and remove the ducts. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6314 1. Position the instrument panel ducts (1 and 5) onto the instrument panel support. 2. Install the three screws that secure each instrument panel duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the instrument panel cover. 4. Position the left side instrument panel duct adapter (6) into the instrument panel and connect it to the left panel duct. 5. Position the intermediate demister ducts (3 and 4) into the instrument panel and connect them to the demister ducts. 6. Install the screw that secures each intermediate demister duct to the instrument panel cover. Tighten the screws to 2.2 N.m (20 in. lbs.). 7. Position the right side instrument panel duct adapter (2) into the instrument panel and connect it to the right panel duct. 8. Position the center distribution duct (2) to the instrument panel support (3). 9. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in. lbs.). 10. Install the defroster duct. 11. Install the radio. 12. Install the instrument panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6315 Air Duct: Service and Repair Duct-Floor Console REMOVAL NOTE: Illustration shown with seat cushions removed for clarity. 1. Remove the floor console. 2. Disengage the floor console duct (1) from the rear duct adapter (3) located at the front of the rear duct (2) below the center front seat and slide the adapter rearward into the rear duct. 3. Disengage the floor console duct from the floor distribution duct (4) located on the bottom of the HVAC housing (5) and remove the console duct from the vehicle. NOTE: Illustration shown with center front seat removed for clarity. 4. If required, remove the front seat and remove the three push-pin retainers (1) that secure the rear duct (2) to the bottom of the center seat support (3). 5. Disengage the rear duct from the rear outlet (4) and remove the rear duct. INSTALLATION NOTE: Illustration shown with center front seat removed for clarity. 1. If removed, install the rear duct (2) onto the rear outlet (4). Make sure the duct is fully engaged to the outlet. 2. Install the three push-pin retainers (1) that secure the rear duct to the front seat support (3) and install the front seat. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6316 NOTE: Illustration shown with seat cushions removed for clarity. 3. Install the floor console duct (1) onto the floor distribution duct (4) located at the bottom of the HVAC housing (5). Make sure the ducts are fully engaged to each other. 4. Slide the rear duct adapter (3) forward and install the floor console duct onto the rear duct (2). Make sure the ducts are fully engaged to each other. 5. Install the floor console. Duct-Defroster REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6317 1. Remove the instrument panel and place it on a workbench. 2. If required, disconnect the center radio speaker wire harness connector (1) and position it the wire harness lead out of the way. 3. Remove the screw (4) that secures the defroster duct adapter (3) to the instrument panel support. 4. Remove the defroster duct adapter from the defroster duct (5). 5. Remove the six screws (2) that secure the defroster duct to the instrument panel. 6. Remove the defroster duct from the instrument panel. INSTALLATION 1. Position the defroster duct (5) into the instrument panel. 2. Install the six screws (2) that secure the defroster duct to the instrument panel. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the defroster duct adapter (3) onto the defroster duct. 4. Install the screw (4) that secures the defroster duct adapter to the instrument panel support. Tighten the screw to 2.2 N.m (20 in. lbs.). 5. If removed, connect the center radio speaker wire harness connector (1) to the speaker. 6. Install the instrument panel. Duct-Floor Distribution NOTE: Regular Cab model shown. Other models similar. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6318 THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the HVAC housing from the vehicle. 2. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 3. Remove the floor distribution duct from the HVAC housing. INSTALLATION 1. Position the floor distribution duct (1) onto the bottom of the HVAC housing (2). 2. Install the screws (3) that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the HVAC housing. Duct-Instrument Panel REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6319 DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench. 2. Remove the radio. 3. Remove the defroster duct. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support (3) and remove the duct. 5. Disconnect the right side instrument panel duct adapter (2) from the right side instrument panel duct (1) and remove the adapter. 6. Remove the screw that secures each intermediate demister duct (3 and 4) to the instrument panel cover. 7. Disconnect the intermediate demister ducts from the demister ducts and remove the intermediate ducts. 8. Disconnect the left side instrument panel duct adapter (6) from the right side instrument panel duct (5) and remove the adapter 9. Remove the instrument panel cover. 10. Remove the three screws that secure each instrument panel duct to the instrument panel support and remove the ducts. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6320 1. Position the instrument panel ducts (1 and 5) onto the instrument panel support. 2. Install the three screws that secure each instrument panel duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the instrument panel cover. 4. Position the left side instrument panel duct adapter (6) into the instrument panel and connect it to the left panel duct. 5. Position the intermediate demister ducts (3 and 4) into the instrument panel and connect them to the demister ducts. 6. Install the screw that secures each intermediate demister duct to the instrument panel cover. Tighten the screws to 2.2 N.m (20 in. lbs.). 7. Position the right side instrument panel duct adapter (2) into the instrument panel and connect it to the right panel duct. 8. Position the center distribution duct (2) to the instrument panel support (3). 9. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in. lbs.). 10. Install the defroster duct. 11. Install the radio. 12. Install the instrument panel. Duct-Instrument Panel Demister REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the instrument panel from cosmetic damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6321 1. Remove the instrument panel and place it on a workbench. 2. Remove the radio. 3. Remove the defroster duct. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support (3) and remove the duct. 5. Disconnect the right side instrument panel duct adapter (2) from the right side instrument panel duct (1) and remove the adapter. 6. Remove the screw that secures each intermediate demister duct (3 and 4) to the instrument panel cover. 7. Disconnect the intermediate demister ducts from the demister ducts and remove the intermediate ducts. 8. Disconnect the left side instrument panel duct adapter (6) from the right side instrument panel duct (5) and remove the adapter 9. Remove the instrument panel cover. 10. Remove the two screws that secure each demister duct to the instrument panel cover and remove the ducts. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6322 1. Position the demister ducts onto the instrument panel cover. 2. Install the two screws that secure each demister duct to the instrument panel cover. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Install the instrument panel cover. 4. Position the left side instrument panel duct adapter (6) into the instrument panel and connect it to the left panel duct. 5. Position the intermediate demister ducts (3 and 4) into the instrument panel and connect them to the demister ducts. 6. Install the screw that secures each intermediate demister duct to the instrument panel cover. Tighten the screws to 2.2 N.m (20 in. lbs.). 7. Position the right side instrument panel duct adapter (2) into the instrument panel and connect it to the right panel duct. 8. Position the center distribution duct (2) to the instrument panel support (3). 9. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2.2 N.m (20 in. lbs.). 10. Install the defroster duct. 11. Install the radio. 12. Install the instrument panel. Outlets - Air - Front Passenger Front Passenger Air Outlet Removal Warning: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative ( ground ) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death. Note: Take the proper precautions to protect the instrument panel from cosmetic damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6323 1. Remove the instrument panel and place it on a workbench. 2. Remove the instrument panel cover from the instrument panel support. Caution: Use care when removing the heads from the heat stakes located on the back of the instrument panel cover. Remove only enough material from the heat stakes to allow removal of the instrument panel air outlet and demister air outlet assembly from the cover. 3. Using an 11 mm (7/16 in) drill bit, carefully remove the heads from the six heat stakes (1) that secure the passenger side air outlet and demister air outlet assembly (2) to the back of the instrument panel cover (3). Caution: Use care when removing the air outlet assembly from the instrument panel cover to prevent damage to the remaining portion of the heat stakes. 4. Carefully remove the air outlet assembly from the instrument panel cover. Installation Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Duct-Floor Console > Page 6324 1. Position the passenger side instrument panel air outlet and demister air outlet assembly (2) onto the back of the instrument panel cover (3). Caution: Always use the retaining screws supplied with the replacement air outlet. Do not use screws longer then 10 mm. Failure to follow this caution may result in damage to the instrument panel cover. Caution: Use care when installing the air outlet retaining screws. To prevent damage to the instrument panel cover, do not overtighten the screws. 2. Install six M 4.2 x 9.5 mm screws (1) to secure the air outlet assembly to the instrument panel cover. Carefully tighten the screws securely. 3. Install the instrument panel cover. 4. Install the instrument panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6328 Sensor - Ambient Air Temperature Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6329 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6330 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation, refer to testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6331 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations HVAC Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6337 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6338 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6339 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Blower Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Motor - Blower Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6358 Blower Motor: Description and Operation The blower motor (1) is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel (3) within the HVAC air inlet housing at the selected speed. The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with an integral wire harness connector (2) and squirrel cage-type blower wheel (3) that is secured to the blower motor shaft (4). The blower wheel is positioned within the air inlet housing on the passenger side end of the HVAC housing. The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the HVAC air inlet housing at the selected speed. The blower motor will operate whenever the ignition switch is in the Run position and the blower motor control is in any position except Off. The blower motor receives battery current through the totally integrated power module (TIPM) whenever the ignition switch is in the Run position. Blower motor speed is controlled by regulating the ground path through or around the blower motor resistor and through the blower motor control located within the A/C-heater control. The blower motor can be accessed for service from underneath the instrument panel. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the resistor block, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. The blower motor control system is diagnosed using a scan tool. The blower motor and blower wheel are factory balanced and cannot be adjusted or repaired. If faulty or damaged, the blower motor and wheel must be replaced as an assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6359 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The blower motor is supplied with a 12V feed from the TIPM, through the resistor block, whenever the ignition switch is in the RUN position. Due to an open circuit condition within the blower motor control switch the TIPM is UNABLE to detect an OPEN circuit for the blower motor. To determine if an open condition exists within the blower motor circuit wiring, it is necessary to disconnect the negative battery cable and check for continuity within the blower motor circuits using an ohmmeter. For circuit descriptions and diagrams, refer to Air Conditioning/Heater in Diagram/Electrical. OPERATION Possible causes of the blower motor not operating include: - Faulty blower motor - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor control Possible causes of the blower motor not operating in one or more speeds include: - Faulty blower motor resistor - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor control VIBRATION Possible causes of blower motor vibration include: - Improper blower motor mounting - Improper blower wheel mounting - Deformed blower wheel - Out of balance blower wheel due to foreign material in the wheel - Faulty blower motor NOISE To determine if the blower motor is the source of the noise, simply switch the blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heating-A/C system. If the noise goes away, possible causes include: - Foreign material in the HVAC air inlet housing - Improper blower motor mounting - Improper blower wheel mounting - Faulty blower motor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Page 6360 Blower Motor: Service and Repair REMOVAL NOTE: The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 1. Disconnect and isolate the negative battery cable. 2. Remove the passenger side cowl trim panel. 3. Disconnect the HVAC wire harness lead (1) from the blower motor (2). 4. Remove the HVAC wire harness lead from the two wire harness retainers (3). 5. Remove the three screws (4) that secure the blower motor to the bottom of the HVAC housing (5). 6. Remove the blower motor from the HVAC housing. INSTALLATION 1. Position the blower motor (2) into the bottom of the HVAC housing (5). 2. Install the three screws (4) that secure the blower motor to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the HVAC wire harness lead (1) to the blower motor and install the wire harness lead into the two wire harness retainers (3). 4. Install the passenger side cowl trim panel. 5. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations HVAC Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6364 Resistor - Blower Motor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6365 Blower Motor Resistor: Description and Operation The blower motor resistor is mounted to the bottom of the HVAC housing, directly behind the glove box. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink (3). The blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and connector of the HVAC wire harness. The blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and connector of the HVAC wire harness. The blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor resistor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6366 Blower Motor Resistor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: For circuit descriptions and diagrams, refer to Diagram/Electrical. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor. 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor speed control and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6367 Blower Motor Resistor: Service and Repair REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR RESISTOR, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTORS TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the negative battery cable. 2. Reach under the instrument panel near the blower motor (5) and disconnect the wire harness connector 2. from the blower motor resistor (4). 3. Remove the two screws (1) that secure the blower motor resistor to the HVAC housing (3). 4. Remove the blower motor resistor from the HVAC housing. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Page 6368 1. Position the blower motor resistor (4) into the opening of the HVAC housing (3) near the blower motor (5). 2. Install the two screws (1) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the wire harness connector (2) to the blower motor resistor. 4. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair This vehicle is not equipped with a cabin air filter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair BODY VENT REMOVAL 1. Remove the rear cab trim panel, Refer to Trim Panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications DENSO A/C COMPRESSOR Air Gap ................................................................................................................................................ ........................ 0.35 - 0.60 mm (0.014 - 0.024 in.) VISTEON A/C COMPRESSOR Air Gap ................................................................................................................................................ ....................... 0.35 - 0.75 mm (0.014 - 0.030 in.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6379 Clutch - A/C Compressor Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 6380 Compressor Clutch: Description and Operation NOTE: Denso 10S17 A/C clutch assembly shown. Visteon HS-18 compressor similar. The A/C compressor clutch assembly consists of a stationary electromagnetic field coil (4), bearing and pulley assembly (3), shims (7) and a clutch plate (2) that is splined to the compressor shaft and secured by a bolt (1). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch bearing and pulley assembly on both A/C compressors are retained to the front of the compressor with a snap ring (6). The A/C clutch field coil on the Denso 10S17 A/C compressor is also retained to the front of the compressor using a snap ring (5). The field coil on the Visteon HS-18 compressor is pressed onto the front of the compressor. The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly. A/C compressor clutch engagement is controlled by the powertrain control module (PCM) or the engine control module (ECM), depending on engine application. When the A/C-heater control is set to any A/C position, it sends a request signal on the CAN-B bus to the totally integrated power module (TIPM), which then transfers the request on the CAN-C Bus to the PCM/ECM, which determines if operating conditions are correct for A/C clutch engagement. When all operating conditions have been met, the PCM/ECM sends a signal on a dedicated hard-wired circuit back to the totally integrated power module (TIPM) to energize the internal A/C clutch high side driver. When energized, the A/C clutch high side driver provides battery current to the A/C clutch field coil. The A/C clutch control system is diagnosed using a scan tool. The A/C compressor clutch components cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compressor Clutch: Initial Inspection and Diagnostic Overview NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. Examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 6383 Compressor Clutch: Component Tests and General Diagnostics After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately 20 times (5 seconds on, then 5 seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6384 Compressor Clutch: Service and Repair DENSO A/C COMPRESSOR REMOVAL NOTE: - The compressor clutch assembly can be serviced with the refrigerant system fully-charged. - Typical A/C compressor shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). 4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor. 5. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2). 6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6385 7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3). 8. Using snap ring pliers (2), remove the snap ring (1) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6386 9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil. INSTALLATION NOTE: Typical A/C compressor shown in illustrations. 1. Align the dowel pin on the back of the compressor clutch field coil (2) with the hole in the front of the A/C compressor (3) and position the field coil onto the compressor. Be certain that the compressor clutch field coil wire lead is properly routed so that it is not pinched between the A/C compressor and the field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the field coil dowel pin location on the A/C compressor. 2. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), install the snap ring (4) that secures the compressor clutch field coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: - Be certain to position the compressor clutch field coil wire lead so that it is not damaged during A/C compressor pulley and bearing Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6387 installation. - When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result. 3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 4. Using snap ring pliers (2), install the snap ring (1) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6388 5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft. 6. Install the clutch plate (4) onto the front of the A/C compressor (5). 7. Install the compressor shaft bolt (3). Tighten the bolt to 19 N.m (168 in. lbs.). NOTE: - The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. - On models with the clutch plate recessed into the pulley, use a 90 degree wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap. 8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained. CAUTION: Be certain that the compressor clutch field coil wire harness is properly routed so that it is not pinched between the A/C compressor and the field coil connector bracket. 9. Carefully route the compressor clutch field coil wire lead behind the connector bracket (2). 10. Install the compressor clutch field coil connector (1) onto the connector bracket. 11. Position the A/C compressor to the engine and install the retaining bolts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6389 12. Connect the engine wire harness to the compressor clutch field coil connector. 13. Install the accessory drive belt. 14. Reconnect the negative battery cable. VISTEON A/C COMPRESSOR REMOVAL NOTE: The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully charged during compressor clutch, pulley and bearing assembly or field coil replacement. 1. Disconnect and isolate negative battery cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. 4. Disconnect the engine wire harness from the clutch field coil connector (4). 5. Remove the bolts that secure the A/C compressor (5) to the mounting bracket. 6. Remove the A/C compressor from the mounting bracket and support the compressor while servicing the clutch. 7. Using compressor clutch holding fixture (Special Tool 9351 in Kit 9349) (1), remove the bolt (2) that secures the clutch plate (3) to the compressor shaft. NOTE: - The clutch plate can be removed from the compressor shaft by hand or, if required, pressed off with an 8 x 1.25 mm bolt. - Clutch plate shim(s) may remain inside the hub of the clutch plate. Be sure to remove all of the shims from inside the hub or from the end of the compressor shaft. 8. Remove the clutch plate and shim(s) from the A/C compressor. If required, install a 8 x 1.25 mm bolt into the center of the clutch plate and turn the bolt clockwise until the clutch plate is completely removed from the A/C compressor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6390 9. Using snap ring pliers (1), remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). NOTE: The pulley and bearing assembly can be removed from the compressor by hand or, if required, with a two jaw puller. 10. Remove the pulley and bearing assembly (1) from the front of the A/C compressor (2). If required, install a two jaw puller (3) and turn the puller center-bolt clockwise until the pulley and bearing assembly is completely removed. 11. Remove the plastic retaining clip (1) and the screw (2) that secures the clutch field coil wire lead and connector (3) to the A/C compressor (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6391 12. Using compressor field coil remover (Special Tool 9354 in Kit 9349) (1) and a two jaw puller (2), remove the clutch field coil (3) from the front of the A/C compressor (4). INSTALLATION 1. Position the A/C clutch field coil (1) squarely onto the front of the A/C compressor (2). CAUTION: Position the A/C clutch field coil so that the coil positioning tabs and the wire harness lead are oriented in the correct direction. Failure to correctly position the field coil on the A/C compressor will result in field coil damage. 2. Align the field coil positioning tabs to the recessed area at the front of the A/C compressor and install the clutch field coil onto the compressor using a two jaw puller (3), compressor field coil installer (Special Tool 9352 in Kit 9349) (4) and the compressor field coil installer spacer (Special Tool 9353 in Kit 9349) (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6392 3. Position the clutch field coil wire lead and connector (3) to the A/C compressor (4) and install the plastic retaining clip (1) and the screw (2) that secures the wire lead to the compressor. Tighten the screw to 4 N.m (35 in. lbs.). 4. Align the pulley and bearing assembly (1) squarely onto the front of the A/C compressor (2). NOTE: A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing. 5. Using clutch pulley installer (Special Tool 9355 in Kit 9349) (3) and a hammer (4), install the pulley and bearing assembly onto the front of the A/C compressor. Tap the installer with a hammer until the pulley and bearing assembly has bottomed against the compressor housing. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in clutch failure and severe damage to the A/C compressor. NOTE: Install the snap ring with the beveled side of the snap ring facing outward. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6393 6. Using snap ring pliers (1), install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor (4). Make sure the snap ring is properly seated in the groove. 7. Verify that there is adequate clearance for the clutch field coil wire lead and connector (4) between the compressor housing and the pulley. NOTE: When installing an original or a new clutch assembly, try the original shims first. When installing a clutch onto a compressor that previously did not have a clutch, use the 1.0, 0.50 and 0.13 millimeter (0.040, 0.020 and 0.005 inch) shims from the clutch hardware package which is provided with the new clutch. 8. Install the clutch shims onto the compressor shaft. 9. Using compressor clutch holding fixture (Special Tool 9351 in Kit 9349) (1), install the bolt (2) that secures the clutch plate (3) to the A/C compressor (5). Hold the clutch plate stationary with the holding fixture and tighten the bolt to 15 N.m (133 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Testing and Inspection > Page 6394 10. Using a feeler gauge (1), check the air gap between the clutch plate (2) and the pulley and bearing assembly (3). If the air gap is not 0.35 to 0.75 millimeter (0.014 to 0.030 inch), add or subtract shims as required. 11. Position the A/C compressor (4) onto the mounting bracket. 12. Install the bolts that secure the A/C compressor to the mounting bracket. Tighten the bolts to 23 N.m (17 ft. lbs.). 13. Connect the engine wire harness to the compressor clutch field coil connector (5). 14. Lower the vehicle. 15. Install the accessory drive belt. 16. Reconnect the negative battery cable. 17. Perform the Clutch Break-in Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection The A/C compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) through the totally integrated power module (TIPM). Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS 1. Using a scan tool, check for diagnostic trouble codes (DTCs) in the A/C-heater control, TIPM, PCM/ECM and if equipped with the 8.3L engine, the gateway module. If no DTCs are found, go to Step 2. If any DTCs are found, repair as required. 2. If the A/C compressor clutch still will not engage, verify the refrigerant charge level. If the refrigerant charge level is OK, go to TESTS . If the refrigerant charge level is not OK, adjust the refrigerant charge as required. TESTS 1. Verify the battery state of charge. 2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. 3. With the A/C-heater control in the A/C mode and the blower motor at low speed, start the engine and allow it to run at a normal idle speed. 4. The A/C compressor clutch should engage immediately, and the clutch coil supply voltage should be within two volts of the battery voltage. If the coil supply voltage is OK, go to Step 5. If the coil supply voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary. 5. For the acceptable A/C clutch coil current draw specifications refer to Heating and Air Conditioning. Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation Condenser HVAC: Description and Operation The A/C condenser is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. The A/C condenser is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. The A/C condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > Page 6401 Condenser HVAC: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the A/C discharge line and the A/C liquid line from the A/C condenser. 4. Disconnect the wire harness connector (8) from the A/C condenser cooling fan motor (7). 5. Remove the two bolts (1 and 9) that secure the A/C condenser to the front upper crossmember (2). 6. Carefully lift the A/C condenser and cooling fan assembly to disconnect the lower mounting tabs (6) from the lower mounting flanges (3) and remove the assembly from the engine compartment. 7. If required, place the A/C condenser and the cooling fan assembly on a workbench and remove the four screws (4 and 5) that secure the cooling fan to the A/C condenser and separate the fan from the condenser. INSTALLATION NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. If removed, install the condenser cooling fan onto the A/C condenser. 2. Install the four screws (4 and 5) that secure the cooling fan to the A/C condenser. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Position the A/C condenser and cooling fan assembly into the engine compartment. 4. Install the lower mounting tabs (6) into the lower mounting flanges (3). 5. Install the two bolts (1 and 9) that secure the A/C condenser to the upper front crossmember (2). Tighten the bolts to 10.5 N.m (95 in. lbs.). 6. Connect the wire harness connector (8) to the A/C condenser cooling fan motor (7). 7. Connect the A/C discharge line and the A/C liquid line onto the A/C condenser. 8. Reconnect the negative battery cable. 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser Fan > Condenser Fan Motor > Component Information > Locations > Page 6406 Motor - Condenser Fan (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions Control Assembly: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6417 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6418 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6419 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6420 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6421 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6422 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6423 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6424 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6425 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6426 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6427 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6428 Control Assembly: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6429 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6430 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6431 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Diagram Information and Instructions > Page 6432 Control Assembly: Connector Views Control - A/C-Heater C1 Control - A/C-Heater C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6433 Control Assembly: Description and Operation MANUAL SINGLE ZONE The A/C-heater control (1) for the manual temperature control (MTC) single zone heating-A/C system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. The A/C-heater control and integral computer located in the instrument panel and contains: - a push button A/C on/off control (2). The Snowflake button contains an LED that illuminates when the A/C system is in operation. - a push button rear window defogger on/off control (3) when equipped with the optional rear heated window. The defogger button contains an LED that illuminates when the rear window defogger (EBL) system is in operation. - a rotary control knob for recirculation and mode control of the discharged air (4). - a rotary control knob for temperature control of the discharged air (5). - a rotary control knob for fan speed selection and turning the heating-A/C system off (6). The A/C-heater control is diagnosed using a scan tool. The A/C-heater control cannot be repaired and, if faulty or damaged, it must be replaced. The illumination lamps for the A/C-heater control are available for service replacement. MANUAL DUAL ZONE The A/C-heater control (1) for the manual temperature control (MTC) dual zone heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. All controls are identified by ISO graphic symbols. The dual zone A/C-heater control and integral computer is located in the instrument panel and contains: - a push button A/C on/off control (2). The Snowflake button contains an LED that illuminates when the A/C system is in operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 6434 - a push button MAX A/C air recirculation control (3). The Recirculation button contains an LED that illuminates when the recirculation function is activated for high A/C demand. - a push button rear window defogger on/off control (4). The defogger button contains an LED that illuminates when the rear window defogger system is in operation. - two slid-type control levers for individual driver and front seat passenger temperature control of the discharged air (5 and 6). - a rotary control knob for mode control of the discharged air (7). - a rotary control knob for fan speed selection and turning the heating-A/C system off (8). The A/C-heater control is diagnosed using a scan tool. The A/C-heater control cannot be repaired and, if faulty or damaged, it must be replaced. The illumination lamps for the A/C-heater control are available for service replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Cool Down Test Control Assembly: Service and Repair A/C Cool Down Test The A/C Cooldown Test: - is actuated with a scan tool. - tests A/C system performance based on evaporator temperature sensor input. - will fail if evaporator temperature is below 13° C (55° F) when initiating the test. - will pass if the evaporator temperature drops 11° C (20° F). - indicates an outcome by displaying one or more test status messages on the scan tool. These test status messages will clear after paging back out of this test function. Therefore, is it important to note all of the messages before doing so. - will cause the A/C status indicator to flash while the test is running. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Cool Down Test > Page 6437 Control Assembly: Service and Repair A/C Heater Control NOTE: Single zone A/C-heater control shown. Dual zone similar. REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel (1) from the instrument panel and disconnect the wire harness connectors (4 and 5) from the back of the A/C-heater control (2). NOTE: Take the proper precautions to protect the front face of the center bezel from cosmetic damage. 3. Place the center bezel on a workbench and remove the four screws (3) that secure the A/Cheater control to the center bezel and remove the control. INSTALLATION 1. Position the A/C-heater control (2) into the back of the instrument panel center bezel (1). 2. Install the four screws (3) that secure the A/C heater control to the center bezel. Tighten the screws to 2.2 N.m (20 in. lbs.). 3. Connect the wire harness connectors (4 and 5) to the back of the A/C-heater control and install the instrument panel center bezel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Cool Down Test > Page 6438 4. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Cool Down Test > Page 6439 Control Assembly: Service and Repair Illumination Lamp WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: There may be minor variations in the locations of the bulb/bulb holder units on the back of the single zone A/C-heater controls as a result of various optional control units. However, the bulb types and service procedures are identical for each of these bulbs. The illumination provisions for the dual zone A/Cheater controls are NOT serviceable. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel from the instrument panel. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (2) counterclockwise about 30 degrees to unlock it from the keyed opening in the A/Cheater control (1) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the bulb holder and bulb (2) with the keyed opening in the circuit board of the A/C-heater control (1). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the center bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6448 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6449 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6450 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6451 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6452 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6453 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6454 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6455 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6456 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6457 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6458 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6459 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6465 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6466 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6467 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6468 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6469 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6470 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6471 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6472 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6473 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6474 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6475 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 6476 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6477 Evaporator Core: Description and Operation The A/C evaporator (1) for the heating-A/C system is located within the HVAC housing, behind the instrument panel. The A/C evaporator and its insulator (2) are positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator. The A/C evaporator can be serviced by removing and disassembling the HVAC housing assembly. Refrigerant enters the A/C evaporator through the A/C orifice tube as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. The A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6478 Evaporator Core: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal and Installation 2. Disassemble the HVAC housing to access the A/C evaporator. See: Housing Assembly HVAC/Service and Repair/Overhaul/HVAC Housing 3. Remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2) and position the wire lead (3) out of the way. NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced. 4. Carefully lift the A/C evaporator and the foam insulator out of the upper half of the HVAC housing (4). NOTE: If the foam seal around the evaporator tapping block is deformed or damaged, the seal must be replaced. 5. If required, remove the foam seal from the inlet and outlet tubes of the A/C evaporator. INSTALLATION NOTE: - If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. - Make sure that the foam insulator is properly positioned in the HVAC housing. 1. Carefully install the A/C evaporator (2) and its foam insulator into the upper half of the HVAC housing (4). 2. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator. 3. Route the wire lead (3) of the evaporator temperature sensor into the opening located on the upper half of the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 6479 4. Assemble the HVAC housing. See: Housing Assembly HVAC/Service and Repair/Overhaul/HVAC Housing 5. Install the HVAC housing. See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/HVAC Housing - Removal and Installation Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations HVAC Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6483 Sensor - Evaporator Temperature Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6484 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the A/C evaporator. The probe (1) for evaporator temperature sensor is attached to the evaporator coil fins. The wire lead (2) for evaporator temperature sensor is routed through an opening at the back of the HVAC housing and the connector (3) is attached to the HVAC wire harness. The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6485 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Remove the wire lead for the evaporator temperature sensor (2) from the retainer located on the HVAC housing (1) and disconnect the sensor connector from the HVAC wire harness (3). 3. Remove the lower half of the HVAC housing from the upper half of the HVAC housing to gain access to the A/C evaporator. 4. Carefully remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2). 5. Remove the wire lead of the evaporator temperature sensor (3) from the upper half of the HVAC housing (4). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6486 1. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator (2). 2. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing (4). 3. Assemble the HVAC housing. 4. Install the wire lead of the evaporator temperature sensor (2) to the retainer located on the HVAC housing (1) and connect the sensor connector to the HVAC wire harness (3). 5. Install the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation The fixed A/C orifice tube is installed in the A/C liquid line and provides a restriction in the liquid refrigerant line between the A/C condenser and the A/C evaporator. This restriction established the pressure differential between the high and low-pressure sides of the A/C system. The A/C orifice tube includes a diffuser screen (1), O-ring seals (2) to seal it to the inner wall of the A/C liquid line, an inlet filter screen (3) and the fixed orifice (4). The fixed A/C orifice tube is used to meter the flow of liquid refrigerant into the A/C evaporator. The high-pressure liquid refrigerant from the A/C condenser expands into a low-pressure liquid as it passes through the metering orifice and diffuser screen of the A/C orifice tube. The A/C orifice tube is not serviceable and cannot be repaired and, if faulty or plugged, the A/C liquid line must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 6490 Expansion Block/Orifice Tube: Testing and Inspection WARNING: THE A/C LIQUID LINE BETWEEN THE A/C CONDENSER AND THE A/C ORIFICE TUBE CAN BECOME HOT ENOUGH TO BURN THE SKIN. USE EXTREME CAUTION WHEN PERFORMING THE FOLLOWING TEST TO PREVENT POSSIBLE PERSONAL INJURY. NOTE: The A/C orifice tube can be checked for proper operation using the following procedure. However, the A/C orifice tube is only serviced as a part of the A/C liquid line. If the results of this test indicate that the A/C orifice tube is obstructed or missing, the A/C liquid line must be replaced. 1. Confirm that the refrigerant system is properly charged. 2. Start the engine. Turn on the A/C system and confirm that the compressor clutch is engaged. 3. Allow the A/C system to operate for five minutes. 4. Lightly and cautiously touch the A/C liquid line near the condenser outlet at the front of the engine compartment. The A/C liquid line should be hot to the touch. 5. Touch the A/C liquid line near the evaporator inlet at the rear of the engine compartment. The A/C liquid line should be cold to the touch. 6. If there is a distinct temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is in good condition. If there is little or no detectable temperature differential between the two ends of the A/C liquid line, the A/C orifice tube is obstructed or missing and the A/C liquid line must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation Heater Core: Description and Operation The heater core (1) is a heat exchanger made of rows of tubes and fins. The heater core is positioned within the HVAC housing through the panel (2) located at the front of the HVAC housing. The heater core tubes (3) are attached to the front of the heater core and are secured to the HVAC housing by a bracket. The heater core can be serviced by removing the HVAC housing assembly from the vehicle. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 6494 Heater Core: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Disassembly of the HVAC housing is not required to remove heater core. 1. Remove the HVAC housing. 2. Remove the foam seal from the heater core tubes. 3. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 4. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 5. Carefully pull the heater core out of the front of the HVAC housing. 6. Inspect all foam seals and replace as required. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 6495 1. Carefully install the heater core (3) into the front of the HVAC housing. 2. Position the heater core tube bracket (2) onto the HVAC housing. 3. Install the two screws (1) that secures the heater core bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 4. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 5. Install the foam seal onto the heater core tubes. NOTE: If the heater core is being replaced, flush the cooling system. 6. Install the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation High Pressure Safety Valve HVAC: Description and Operation A high pressure relief valve is located on the A/C compressor. This mechanical valve is designed to vent refrigerant from the A/C system to protect against damage to the A/C compressor and other A/C system components, caused by condenser air flow restriction or an overcharge of refrigerant. The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. The majority of the refrigerant is conserved in the A/C system. If the high pressure relief valve vents refrigerant, it does not mean the valve is faulty. The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions WARNING: - THE A/C SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE A/C REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION AND DEATH. - THE EVAPORATION RATE OF R-134A REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134A SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES UP TO 145 KILOPASCALS (21 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. CAUTION - Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. - Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. - Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line Hose/Line HVAC: Description and Operation Coupler-Refrigerant Line Spring-lock type refrigerant line couplers (1 and 4) are used to connect the A/C suction line (6) to the A/C accumulator (5) and, the A/C accumulator and the A/C liquid line to the A/C evaporator tubes (3). Secondary retaining clips (2 and 7) are installed over the connected couplers for added protection. The spring-lock refrigerant line couplers require special disconnect tools for disengaging the two coupler halves. The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected. Two O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. A secondary retaining clip (3) is installed over the connected coupler (5) for added protection. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6504 Hose/Line HVAC: Description and Operation Plumbing The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80 millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s). High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6505 Hose/Line HVAC: Description and Operation Line-A/C Discharge The A/C discharge line is the refrigerant line that goes from the A/C compressor to the A/C condenser and has an integral fitting for the A/C pressure transducer. The A/C discharge line for the 5.9L Diesel engine is serviced as an assembly with the suction line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use correct O-ring seal will cause the refrigerant system connection to leak. The A/C discharge line has no serviceable parts except the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is removed and installed. If the A/C discharge line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6506 Hose/Line HVAC: Description and Operation Line-A/C Liquid The liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The liquid line for this model consist of two separate lines that connect to each other using a spring-lock type refrigerant line coupler. The liquid lines are made from light-weight aluminum, and use braze-less fittings. The front half of the liquid line includes the high-side service port and the rear half of the liquid line contains the fixed orifice tube. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is removed and installed. If the liquid line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Coupler-Refrigerant Line > Page 6507 Hose/Line HVAC: Description and Operation Line-A/C Suction The A/C suction line is the refrigerant line that goes from the A/C evaporator to the A/C compressor. The A/C suction line for the 5.9L Diesel engine is serviced as an assembly with the discharge line. The A/C discharge line for the 8.3L engine is secured to the top of fan shroud by two retainers. CAUTION: Use only O-ring seals specified for the vehicle. Failure to use the correct O-ring seal will cause the refrigerant system connections to leak. The A/C suction line has no serviceable parts except for the rubber O-ring seals and the secondary retaining clip. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is removed and installed. If the A/C suction line is found to be leaking or is damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 6508 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR AND R-134A CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134A SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. NOTE: - If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location. - The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system. Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi) , proceed to SYSTEM EMPTY . If greater than 345 kPa (50 psi), go to SYSTEM LOW. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to Step 2. 2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to Step 1 of the System Low procedure. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Operate the heating-A/C system with the engine at idle under the following conditions for at least five minutes. - Doors or windows open - Transmission in Park or Neutral with the parking brake set (depending on application) - A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system. 3. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line Hose/Line HVAC: Service and Repair Coupler-Refrigerant Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1). 4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting. 6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4). INSTALLATION 1. Clean any dirt or foreign material from the springlock type refrigerant line coupler. 2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6511 CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any other O-rings may allow the connection to leak. 3. Install new O-rings (8) on the male half of the refrigerant line coupler. 4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Position the female half of the coupler over the male half of the coupler. 6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler. 7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler. 8. Install the secondary retaining clip (3) over connected coupler cage (5). 9. Evacuate the refrigerant system. 10. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6512 Hose/Line HVAC: Service and Repair Line-A/C Discharge REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the wire harness connector from the A/C pressure transducer (8). 4. Remove the nut (2) that secures the A/C discharge line (1) to the A/C condenser (3). 5. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring and dual plan seal. 6. Install plugs in, or tape over the discharge line fitting and condenser inlet port. 7. Remove the nut (7) that secures the A/C discharge line to the A/C compressor (6). 8. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring and dual plan seal. 9. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 10. Remove the A/C discharge line from the engine compartment. 11. If necessary, remove the A/C pressure transducer from the A/C discharge line. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6513 1. If removed, install the A/C pressure transducer (8) onto the A/C discharge line (1). 2. Position the A/C discharge line into the engine compartment. 3. Remove the tape or plugs from the opened discharge line fitting and the inlet port on the A/C condenser (3). 4. Lubricate a new O-ring and dual plane seal with clean refrigerant oil and install them onto the discharge line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Install the A/C discharge line onto the A/C condenser. 6. Install the nut (2) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 20 N.m (15 ft. lbs.). 7. Remove the tape or plugs from the opened discharge line fitting and the outlet port on the A/C compressor (6). 8. Lubricate a new O-ring and dual plane seal with clean refrigerant oil and install them onto the discharge line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C discharge line onto the A/C compressor. 10. Install the nut (7) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.). 11. Connect the wire harness connector to the A/C pressure transducer. 12. Reconnect the negative battery cable. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6514 Hose/Line HVAC: Service and Repair Line-A/C Liquid WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The A/C liquid line is serviced in two sections. FRONT SECTION REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing and mounting bracket. 5. Remove the plastic cover from the condenser outlet stud. 6. Remove the nut (8) that secures the front section of the A/C liquid line (10) to the A/C condenser (7). 7. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring and dual plane seal. 8. Disengage the A/C liquid line from the body retaining clips (1 and 9). 9. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line (4). 10. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the O-ring seals. 11. Install plugs in, or tape over the opened ends of the A/C liquid lines and the condenser outlet port. 12. Remove the front section of the A/C liquid line from the engine compartment. INSTALLATION NOTE: The A/C liquid line is serviced in two sections. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6515 1. Position the front section of the A/C liquid line (10) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the condenser outlet port. 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C liquid line to the rear section of the liquid line (4). 5. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line onto the rear section of the liquid line. 6. Engage the A/C liquid line into the body retaining clips (1 and 9). 7. Lubricate a new O-ring and dual plane seal with clean refrigerant oil and install them onto the front liquid line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line to the outlet port of the A/C condenser (7). 9. Install the nut (8) that secures the A/C liquid line to the A/C condenser. Tighten the nut to 20 N.m (15 ft. lbs.). 10. Install the plastic cover onto the condenser outlet stud. 11. If equipped with a gasoline engine, install the air filter housing mounting bracket and air filter housing. 12. If equipped with the diesel engine, install the passenger side battery tray. 13. Reconnect the negative battery cable(s). 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. REAR SECTION REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6516 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. If equipped with the diesel engine, remove the passenger side battery. 4. If equipped with a gasoline engine, remove the air filter housing and mounting bracket. 5. Disengage the rear section of the A/C liquid line (4) from the body retaining clip (3). 6. Remove the secondary retaining clip (2) from the spring-lock coupler that secures the front section of the A/C liquid line (10) to the rear section of the liquid line. 7. Using the proper A/C line disconnect tool, disconnect the front section of the A/C liquid line from the rear section of the liquid line and remove and discard the seal. 8. Remove the secondary retaining clip (5) from the spring-lock coupler that secures the rear section of the A/C liquid line to the evaporator inlet tube (6). 9. Using the proper A/C line disconnect tool, disconnect the A/C liquid line from the evaporator inlet tube and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened ends of the A/C liquid lines and the evaporator inlet port. 11. Remove the rear section of the A/C liquid line from the engine compartment. INSTALLATION 1. Position the rear section of the A/C liquid line (4) into the engine compartment. 2. Remove the tape or plugs from the opened ends of the A/C liquid lines and the evaporator inlet tube (6). 3. Lubricate new O-ring seals with clean refrigerant oil and install them onto the rear liquid line spring-lock coupler fitting. Use only the specified seas as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6517 vehicle. 4. Connect the rear section of the A/C liquid line to the evaporator inlet tube. 5. Install the secondary retaining clip (5) onto the spring-lock coupler that secures the rear section of the A/C liquid line onto the evaporator inlet tube. 6. Engage the A/C liquid line into the body retaining clip (3). 7. Lubricate new O-ring seals with clean refrigerant oil and install them onto the front liquid line spring-lock coupler fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the rear section of the A/C liquid line to the front section of the liquid line (10). 9. Install the secondary retaining clip (2) onto the spring-lock coupler that secures the front section of the A/C liquid line to the rear section of the liquid line. 10. If equipped with a gasoline engine, install the air filter housing mounting bracket and air filter housing. 11. If equipped with the diesel engine, install the passenger side battery tray. 12. Reconnect the negative battery cable(s). 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6518 Hose/Line HVAC: Service and Repair Line-A/C Suction REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air filter housing. 4. Remove the nut (4) that secures the A/C suction line (5) to the A/C compressor (6). 5. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring and dual plane seal. 6. Install plugs in, or tape over the opened refrigerant line fitting and the compressor port. 7. Remove the secondary retaining clip (7) from the spring-lock coupler (1) that secures the A/C suction line (6) to the A/C accumulator (5). 8. Using the proper A/C line disconnect tool, disconnect the A/C suction line from the A/C accumulator and remove and discard the O-ring seals. 9. Install plugs in, or tape over the opened suction line fitting and the accumulator outlet tube. 10. Remove the A/C suction line from the engine compartment. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Coupler-Refrigerant Line > Page 6519 1. Position the A/C suction line (5) into the engine compartment. 2. Remove the tape or plugs from the opened fitting on the A/C suction line and the inlet port on the A/C compressor (6). 3. Lubricate a new O-ring and dual plan seal with clean refrigerant oil and install them onto the suction line fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the A/C suction line onto the A/C compressor. 5. Install the nut (4) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 20 N.m (15 ft. lbs.). 6. Remove the tape or plugs from the opened suction line fitting and the accumulator outlet tube. 7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the accumulator tube fitting. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the A/C suction line (6) to the spring-lock coupler (1) on the accumulator (5) and install the secondary retaining clip (7) 9. Install the air filter housing cover. 10. Reconnect the negative battery cable. 11. Evacuate the refrigerant system. 12. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation Housing Assembly HVAC: Description and Operation All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of the following: - HVAC housing-The HVAC housing consists of an upper housing (7) and a lower housing (10) that are attached together by screws and is mounted to the dash panel behind the instrument panel. The HVAC housing contains the heater core (9), A/C evaporator (15), blend-air and mode- air doors, and has mounting provisions for the air-door actuators (3, 5, 6 and 8), floor distribution duct (4), blower motor (13), blower motor resistor, foam seals (12, 14 and 16) and the HVAC wire harness (11). - Air inlet housing-The air inlet housing (1) is mounted to the right end of the HVAC housing and contains the recirculation-air door and has mounting provisions for the recirculation door actuator (2). The heating-A/C system is a blend-air type system. The blend-air doors control the amount of conditioned air that is allowed to flow through, or around, the heater core. The dual zone heating A/C system uses two blend door actuators while the single zone system uses only one blend door actuator. The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator(s), which moves the blend-air door(s). This allows an almost immediate control of the output air temperature of the system. The mode door actuator operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric door actuators are connected to the vehicle electrical system by the HVAC wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housings at the selected speed by use of the blower motor resistor. The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, evaporator temperature sensor, blend-air and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Air Inlet Housing Removal and Installation AIR INLET HOUSING WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Vehicle Damage Warnings Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door only See: Air Door NOTE: The air inlet housing does not need to be removed from the HVAC housing for service of the recirculation-air door only See: Air Door 1. Disconnect and isolate the negative battery cable. 2. Drain the engine cooling system. 3. Disconnect the heater hoses from the heater core tubes. 4. Remove the Powertrain Control Module (PCM) to gain access to the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts See: Powertrain Management/Computers and Control Systems/Engine Control Module 5. Remove the instrument panel from the passenger compartment See: Body and Frame/Interior Moulding / Trim 6. Remove the bolt (5) that secures the HVAC housing (4) to the floor bracket (6). 7. Remove the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6525 8. Carefully pull the right side of the HVAC housing rearward to gain access to the front of the air inlet housing. 9. Remove the recirculation door actuator (1) from the air inlet housing (2) and disconnect the HVAC wire harness (4) from the actuator. 10. Remove the two screws (3) that secure the rear of the air inlet housing to the top of the HVAC housing (5). 11. Release the two retaining clips (1) that secure the front of the air inlet housing (2) to the top of the HVAC housing (3) and remove the air inlet housing. NOTE:If the foam seal on the air inlet housing is deformed or damaged, it must be replaced. 12. If required, disassemble the air inlet housing See: Overhaul Installation NOTE: If the foam seal on the air Inlet housing is deformed or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6526 1. Position the air inlet housing (2) onto the top of the HVAC housing (3). 2. Engage the two retaining clips (1) that secure the front of the air inlet housing to the HVAC housing. 3. Install the two screws (3) that secure the rear of the air inlet housing (2) to the top of the HVAC housing (5). Tighten the screws to 1.1 N.m (10 in. lbs.). 4. Install the recirculation door actuator (1) onto the air inlet housing See: Air Door 5. Connect the HVAC wire harness (4) to the recirculation door actuator. 6. If removed, install the fresh air inlet (2) onto the dash panel (1). 7. Reposition the HVAC housing (4) to the passenger compartment with the mounting studs and the condensate drain tube in their proper locations in the dash panel. 8. Install the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 6.8 N.m (60 in. lbs.). 9. Install the bolt (5) that secures the HVAC housing to the floor bracket (6). Tighten the bolt to 6.8 N.m (60 in.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6527 10. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim 11. Install the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2). Tighten the nuts to 6.8 N.m (60 in. lbs.). 12. Install the Powertrain Control Module See: Powertrain Management/Computers and Control Systems/Engine Control Module 13. Connect the heater hoses to the heater core tubes. 14. Reconnect the negative battery cable. 15. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System 16. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection HVAC Housing - Removal and Installation NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. REMOVAL WARNING: - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6528 2. Drain the engine cooling system. 3. Disconnect and isolate the negative battery cable. 4. Disconnect the A/C liquid line and the A/C accumulator from the A/C evaporator. 5. Disconnect the heater hoses from the heater core tubes. 6. Remove the powertrain control module (PCM) to gain access to the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2) and remove the nuts. 7. On Mega Cab models, remove the floor console duct. 8. Remove the instrument panel from the passenger compartment. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel 9. Remove the bolt (5) that secures the HVAC housing (4) to the floor bracket (6). 10. Remove the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel (1). 11. Pull the HVAC housing assembly rearward and remove the housing assembly from the passenger compartment. 12. If required, remove the fresh air inlet (2) from the dash panel (1). INSTALLATION 1. If removed, install the fresh air inlet (2) onto the dash panel (1). 2. Position the HVAC housing assembly (4) into the passenger compartment with the mounting studs and the condensate drain tube in their proper locations in the dash panel. 3. Install the two nuts (3 and 7) that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the nuts to 6.2 N.m (55 in.lbs.). 4. Install the bolt (5) that secures the HVAC housing to the floor bracket (6). Tighten the bolt to 6.2 N.m (55 in. lbs.). 5. Install the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel 6. On Mega Cab models, install the floor console duct. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6529 7. Install the two nuts (3) that secure the HVAC housing (1) to the engine compartment side of the dash panel (2). Tighten the nuts to 6.2 N.m (55 in. lbs.). 8. Install the powertrain control module (PCM). 9. Connect the heater hoses to the heater core tubes. 10. Connect the A/C liquid line and the A/C accumulator to the A/C evaporator. 11. Reconnect the negative battery cable. 12. If the heater core is being replaced, flush the cooling system. 13. Refill the engine cooling system. 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6530 Housing Assembly HVAC: Overhaul Air Inlet Housing DISASSEMBLY NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. 1. Remove the air inlet housing (1) from the HVAC housing and place it on a workbench. 2. Remove the two foam insulators (2) from the air inlet housing. 3. To remove the recirculation-air door (1) from the air inlet housing (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the air inlet housing and pull the actuator coupler out of the pivot shaft of the recirculation-air door. NOTE: If the seals on the air door is deformed or damaged, the air door must be replaced. 4. Remove the recirculation-air door from the air inlet housing. ASSEMBLY NOTE: - The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. - If the seals on the air door is deformed or damaged, the air door must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6531 1. Position the recirculation-air door (1) into the air inlet housing (2). CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seat located in the air inlet housing. 2. Align the actuator coupler (3) with the recirculation air door pivot shaft and install the coupler until the coupler retaining tabs are fully engaged to the air inlet housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the air inlet housing. 3. Install the two foam insulators (2) into the air inlet housing (1). 4. Install the air inlet housing onto the HVAC housing. HVAC Housing DISASSEMBLY NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, evaporator temperature sensor, mode-air and blend-air doors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6532 1. Remove the HVAC housing assembly and place it on a workbench. 2. Disconnect the HVAC wire harness connectors from the mode door actuators (1), blend door actuators (2) and the recirculation door actuator (3). 3. Remove the screws that secure the mode door actuators and the blend door actuators to the HVAC housing (5) and remove the actuators. 4. Remove the screws that secure the recirculation door actuator to the air inlet housing (4) and remove the actuator. 5. Disconnect the wire harness connectors (1 and 3) from the blower motor resistor (7) and the blower motor (2). 6. Remove the screws (4) that secure the blower motor to the HVAC housing (5) and remove the blower motor. 7. Remove the screws (6) that secure the blower motor resistor to the HVAC housing and remove the resistor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6533 8. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2) and remove the HVAC wiring harness from the HVAC housing (4). 9. Remove the air inlet housing (3) from the HVAC housing. 10. Remove the two screws (1) that secure the panel/floor door outlet (2) to the top of the HVAC housing (4). NOTE: If the foam seal on the panel/floor door outlet is deformed or damaged, it must be replaced. 11. Release the two retaining tabs (3) that secure the panel/floor door outlet to the front of the HVAC housing and remove the door outlet. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6534 12. Remove the three screws (1) that secure the panel/floor door assembly (2) to the top of the HVAC housing (3) and remove the door assembly. 13. To remove the panel/floor-air doors (1) from the panel/floor door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the door plate and pull the actuator coupler out of the pivot shaft of the panel/floor-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 14. Remove the panel/floor-air doors from the panel/floor door plate. NOTE: If the foam seal for the heater core tubes is deformed or damaged, the seal must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6535 15. Remove the foam seal from the heater core tubes. 16. If equipped with the dual zone heating-A/C system, remove the linkage rod (4) to gain access to the heater core (3). 17. Remove the two screws (1) that secure the heater core tube bracket (2) to the HVAC housing and remove the bracket. 18. Carefully pull the heater core out of the front of the HVAC housing. 19. Inspect all heater core foam seals and replace as required. 20. Remove the screws (3) that secure the floor distribution duct (1) to the bottom of the HVAC housing (2). 21. Remove the floor distribution duct from the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6536 22. Carefully disconnect the linkage rod (1) from the two blend-air door levers (2) located on the back of the HVAC housing (3). NOTE: If the foam seal for the evaporator condensate drain tube is deformed or damaged, the seal must be replaced. 23. Remove the foam seal (4) from the evaporator condensate drain tube (5). 24. Remove the fifteen screws (6) that secure the upper and lower HVAC housing halves together and separate the housing halves. 25. Release the three retaining tabs (1) that secure the lower blend door assembly (2) to the lower half of the HVAC housing (3) and remove the door assembly. 26. Release the three retaining tabs that secure the upper blend door assembly to the upper half of the HVAC housing and remove the door assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6537 27. To remove the blend-air doors (1) from each blend door plate (2), first carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the door plate being serviced and pull the actuator coupler out of the pivot shaft of the blend-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 28. Remove the blend-air doors from the blend door plates. 29. Remove the defroster-air doors (1) from the lower half of the HVAC housing (2) by carefully release the retaining tabs of actuator coupler (3) located on the inside surface of the housing and pull the actuator coupler out of the pivot shaft of the defroster-air doors. NOTE: If the seals on the air doors is deformed or damaged, the air doors must be replaced. 30. Remove the defroster-air doors from the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6538 31. Remove the insulator (1) from the A/C evaporator (5). 32. Remove the probe of the evaporator temperature sensor (2) from the fins of the A/C evaporator. NOTE: If the foam seal for the A/C evaporator tubes is deformed or damaged, the seal must be replaced. 33. Remove the foam seal (3) from the tubes of the A/C evaporator. NOTE: If the foam seal around the A/C evaporator is deformed or damaged, the seal must be replaced. 34. Carefully lift the A/C evaporator out of the upper half of the HVAC housing (4). ASSEMBLY 1. Carefully install the A/C evaporator (2) into the upper half of the HVAC housing (4). 2. Install the foam seal (3) onto the tubes of the A/C evaporator. 3. Install the probe of the evaporator temperature sensor (2) between the fins of the A/C evaporator. 4. Install the insulator (1) onto the bottom of the A/C evaporator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6539 5. Install the defroster-air doors (1) into the lower half of the HVAC housing (2). 6. Align the actuator coupler (3) with the defroster-air door pivot shaft and install the coupler into side of the HVAC housing. Be sure to install the coupler with the coupler arm located between the two stop tabs on the HVAC housing. 7. Install the blend-air doors (1) into each of the two blend door plates (2). 8. Align the actuator coupler (3) with each blend-air door pivot shaft and install the coupler into side of each blend door plate. Be sure to install each coupler with the coupler arm located between the two stop tabs on each blend door plate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6540 9. Position the lower blend door assembly (2) into the lower half of the HVAC housing (3) and fully engage the three retaining tabs (1). 10. Position the upper blend door assembly into the upper half of the HVAC housing and fully engage the three retaining tabs. NOTE: Route the wire lead for the evaporator temperature sensor into the opening located on the upper half of the HVAC housing prior to installing the lower half of the HVAC housing. 11. Position the two halves of the HVAC housing together (3). 12. Install the fifteen screws (6) that secure the two housing halves together. Tighten the screws to 2.2 N.m (20 in. lbs.). 13. Install the foam seal (4) onto the evaporator condensate drain tube (5). 14. Connect the linkage rod (1) to the two blend-air door levers (2) located on the back of the HVAC housing. 15. Position the front floor distribution duct (1) to the bottom of the HVAC housing (2). 16. Install the screws (3) that secure the front floor distribution duct to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6541 17. Carefully install the heater core (3) into the front of the HVAC housing. 18. Position the heater core tube bracket (2) onto the HVAC housing. 19. Install the two screws (1) that secures the heater core bracket to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 20. If equipped with the dual zone heating-A/C system, install the linkage rod (4). 21. Install the foam seal onto the heater core tubes. 22. Install the panel/floor-air doors (1) into the panel/floor door plate (2). 23. Align the actuator coupler (3) with the panel/floor air door pivot shaft and install the coupler into side of the panel/floor door plate. Be sure to install the coupler with the coupler arm located between the two stop tabs on the door plate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6542 24. Position the panel/floor door assembly (2) onto the top of the HVAC housing (3). NOTE: Install the two door springs onto the retaining screws prior to installation. 25. Install the three screws (2) that secure the door assembly to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 26. Position the panel/floor door outlet (2) onto the top of the HVAC housing (3) and fully engage the two retaining tabs (3). 27. Install the two screws (1) that secure the panel/floor door outlet to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6543 28. Install the air inlet housing (3) onto the top of the HVAC housing (4). 29. Install the HVAC wire harness (1) onto the HVAC housing. Make sure the wires are routed through all wiring retainers. 30. Connect the HVAC wire harness to evaporator temperature sensor (2). 31. Position the blower motor resistor (7) and the blower motor (2) into the bottom of the HVAC housing (5). 32. Install the screws (4 and 6) that secure the blower motor resistor and the blower motor to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.). 33. Connect the HVAC wire harness connectors (1 and 3) to blower motor resistor and the blower motor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 6544 34. Position the recirculation door actuator (3) onto the air inlet housing (4) and install the retaining screws. Tighten the screws to 2.2 N.m (20 in.lbs.) . 35. Position the mode door actuators (1) and the blend door actuators (2) onto the HVAC housing (5) and install the retaining screws. Tighten the screws to 2.2 N.m (20 in. lbs.). 36. Connect the HVAC wire harness connectors to the actuators. 37. Install the HVAC housing assembly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications R-134a Refrigerent Charge Capacity 1. 3.7/4.7/5.7/8.3 L ............................................................................................................................... ........................................... 0.728 kg (1.604 lbs.) 2. 5.9 L ................................................................... ....................................................................................................................... 0.850 kg (1.873 lbs.) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 6549 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6550 Refrigerant: Description and Operation The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 6551 Refrigerant: Service and Repair WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Always refer to the Underhood HVAC Specification Label for the refrigerant fill specification of the vehicle being serviced. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the Underhood HVAC Specification Label. An R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. 1. Evacuate the refrigerant system. 2. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle ( about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: TAKE CARE NOT TO OPEN THE DISCHARGE (HIGH PRESSURE) VALVE AT THIS TIME. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 6556 Refrigerant Oil: Fluid Type Specifications Denso 10S17 A/C Compressor ........................................................................................................... ........................................................... ND-8 PAG Oil Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6557 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. Use only refrigerant oil of the same type as recommended to service the refrigerant system (always refer to the specification tag included with the replacement A/C compressor or the A/C Underhood Specification Label located in the engine compartment). The Denso 10S17 A/C compressor used in this vehicle when equipped with the 3.7L, 4.7L, 5.7L or 8.3L engine is designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil when servicing the A/C compressor for these engines. The Visteon HS-18 A/C compressor used in this vehicle when equipped with 5.9L diesel engine is designed to use VC-46 PAG refrigerant oil. Use only this type of refrigerant oil when servicing this A/C compressor. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 6558 Refrigerant Oil: Service and Repair When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The accumulator, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The refrigerant oil in the R-134a A/C system is unique depending on the A/C compressor used. Use only PAG oils that are designed to work with R-134a refrigerant and the A/C compressor in the vehicle. Always refer to the A/C Underhood Specification Label for the correct oil designation. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when an accumulator, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. When an A/C compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer - A/C Pressure (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6562 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10 ° C (50° F) due to the pressure/ temperature relationship of the refrigerant. The A/C pressure transducer input to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6563 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6568 Sensor - Ambient Air Temperature Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6569 Ambient Temperature Sensor / Switch HVAC: Description and Operation The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the left side of the radiator yoke, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Front Control Module (FCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the FCM. Based upon the resistance in the sensor, the FCM senses a specific voltage on the temperature sensor signal circuit. The FCM then translates the voltage into a temperature reading that it sent over the Programmable Communications Interface (PCI) data bus circuit to other modules utilizing temperature information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6570 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection The temperature function is supported by the ambient temperature sensor, a wiring circuit, and Front Control Module (FCM). If any portion of the ambient temperature sensor circuit fails or if Programmable Communications Interface (PCI) Data Bus information is missing, a (- -) will appear in the display in place of the temperature. When the sensor is exposed to temperatures above 55° C (130° F), or if the sensor circuit is shorted, 55° C (130° F) will appear in the display in place of the temperature, when the sensor is exposed to temperatures below - 40° C (- 40° F) or if the sensor circuit is open, - 40° C (- 40° F) will appear in the display. The ambient temperature sensor circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, test the compass mini-trip computer. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilohms. At 55° C (130° F), the sensor resistance is 2.488 kilohms. The sensor resistance should read between these two values. If OK, refer to Sensor Circuit Test. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the wire harness connectors from the ambient temperature sensor and the FCM. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the FCM harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Check for continuity between the ambient temperature sensor signal circuit cavity of the FCM harness connector and a good ground. There should be no continuity. If OK, test the compass mini-trip computer operation, refer to testing. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 6571 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Open the hood. 2. Disconnect and isolate the battery negative cable. 3. Working on the underside of the hood, remove screw holding sensor to hood panel. 4. Disconnect the sensor electrical connector and remove sensor from vehicle. INSTALLATION 1. Connect the sensor electrical connector. 2. Working on the underside of the hood, install screw holding sensor to hood panel. 3. Connect the battery negative cable. 4. Close the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations HVAC Assembly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6575 Sensor - Evaporator Temperature Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6576 Evaporator Temperature Sensor / Switch: Description and Operation The evaporator temperature sensor is a two-wire temperature sensing element located at the coldest point on the face of the A/C evaporator. The probe (1) for evaporator temperature sensor is attached to the evaporator coil fins. The wire lead (2) for evaporator temperature sensor is routed through an opening at the back of the HVAC housing and the connector (3) is attached to the HVAC wire harness. The evaporator temperature sensor monitors the surface temperature of A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. The A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature. The A/C heater control is programmed to respond to this input by requesting the powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) to cycle the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor is diagnosed using a scan tool. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6577 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. Remove the HVAC housing and place it on a workbench. 2. Remove the wire lead for the evaporator temperature sensor (2) from the retainer located on the HVAC housing (1) and disconnect the sensor connector from the HVAC wire harness (3). 3. Remove the lower half of the HVAC housing from the upper half of the HVAC housing to gain access to the A/C evaporator. 4. Carefully remove the probe of the evaporator temperature sensor (1) from the fins of the A/C evaporator (2). 5. Remove the wire lead of the evaporator temperature sensor (3) from the upper half of the HVAC housing (4). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 6578 1. Install the probe of the evaporator temperature sensor (1) between the fins of the A/C evaporator (2). 2. Route the wire lead for the evaporator temperature sensor (3) into the opening located on the upper half of the HVAC housing (4). 3. Assemble the HVAC housing. 4. Install the wire lead of the evaporator temperature sensor (2) to the retainer located on the HVAC housing (1) and connect the sensor connector to the HVAC wire harness (3). 5. Install the HVAC housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams Transducer - A/C Pressure (NGC) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6582 Refrigerant Pressure Sensor / Switch: Description and Operation The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the A/C discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the A/C discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. The powertrain control module (PCM) or the engine control module (ECM) (depending on engine application) provides a five volt reference signal and a sensor ground to the A/C pressure transducer, then monitors the output voltage of the transducer on a sensor return circuit to determine refrigerant pressure. The PCM/ECM is programmed to respond to this and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3172 kPa (460 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer signal to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10 ° C (50° F) due to the pressure/ temperature relationship of the refrigerant. The A/C pressure transducer input to the PCM/ECM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 10° C (50° F) due to the pressure/temperature relationship of the refrigerant. The A/C pressure transducer is diagnosed using a scan tool. The A/C pressure transducer cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Diagrams > Page 6583 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2) located on the A/C discharge line (3). 3. Remove the A/C pressure transducer from the fitting on the A/C discharge line and remove and discard the O-ring seal. INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the A/C discharge line. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant system. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant. The high side service port is located on the A/C discharge line. The A/C pressure transducer is mounted on the high side service port. The low side service port is located either on the top of the A/C accumulator or on the A/C suction line near the accumulator, depending on engine application. Both the high side and low side A/C service port valve cores are serviceable. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 6587 Service Port HVAC: Service and Repair NOTE: Typical A/C service port shown. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in or tape over the opened service port(s). INSTALLATION 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 6588 NOTE: The protective cap helps aid in service port sealing and helps protect the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 6. Install the protective cap (1) onto the service port. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair Any vehicle which is to be returned to use following a supplemental restraint deployment, must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring must be replaced. If the passenger airbag is deployed, the passenger airbag door must be replaced. The seat belt tensioners are deployed by the same signal that deploys the driver and passenger airbags and must also be replaced if either front airbag has been deployed. If a side curtain airbag has been deployed, the complete airbag unit, the headliner, as well as the upper A, B, and C-pillar trim must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a supplemental restraint deployment, which may or may not be obvious during a visual inspection. On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected following a side curtain airbag deployment. It is also critical that the mounting surfaces and/or mounting brackets for the Occupant Restraint Controller (ORC), side impact sensors, and front impact sensors be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ORC and each front and side impact sensor are used by the supplemental restraint system to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required. All other vehicle components should be closely inspected following any supplemental restraint deployment, but are to be replaced only as required by the extent of the visible damage incurred. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 6598 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 6599 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag: Recalls Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement Technical Service Bulletin # F40 Date: 060901 Recall - Passenger Air Bag Cushion Replacement September 2006 Dealer Service Instructions for: Safety Recall F40 Passenger Airbag Cushion Models 2006 (DR) Dodge Ram Pick up Truck (1500 Series) NOTE: This recall applies only to the above vehicles built with Advanced Multistage Front Airbags (sales code CG3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The passenger airbag on about 144,000 of the above vehicles may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. This can increase the risk of injury to a child seat occupant during certain crash conditions. As a result, these vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 208 Occupant Crash Protection. Repair The passenger airbag cushion must be replaced and the Occupant Restraint Controller (ORC) must be reprogrammed (flashed). NOTE: The owner notification for this recall will be delayed until an adequate quantity of parts is available. Parts Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6612 Special Tools Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6613 vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect and isolate the negative battery cable. Wait two minutes for the system capacitor to discharge before further service. WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before replacing the passenger airbag cushion. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 2. Using a plastic trim stick, remove the windshield trim bezel from the instrument panel. 3. Remove the glove box assembly from the instrument panel by squeezing the sides inward and rolling the door downward (Figure 1) 4. Disengage the airbag inflator pigtail wire connector from the plastic push-in retainer plate on the right side of the instrument panel airbag support bracket by: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6614 a. Using a small screwdriver, carefully pry the leading edge of the push-in retainer plate away from the connector insulator far enough to clear the engagement tab on the insulator (Figure 2). b. Pull the connector toward you to slide it off of the push-in retainer plate. 5. Disconnect the instrument panel wire harness connector from the yellow airbag inflator pigtail wire connector on the right side of the instrument panel airbag support bracket (Figure 3). To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 6. Remove the two airbag module mounting bolts that secure the passenger airbag lower bracket to the instrument panel airbag support bracket (Figure 3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6615 7. Using a plastic trim stick, gently pry on the outboard edges of the passenger airbag door/cover to disengage the snap features from the receptacles in the instrument panel (Figure 4). 8. Remove the passenger airbag assembly from the instrument panel. 9. Mount the airbag assembly in a bench vise as shown in Figure 5. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6616 10. Remove the airbag plastic door/cover by rolling the cover off the retaining fingers (Figure 6). 11. Remove and save the four airbag cushion retaining nuts (Figure 7). 12. Remove the inflator bracket (Figure 7). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6617 13. Carefully remove the airbag cushion from the inflator assembly (Figure 8). 14. Install the new airbag cushion into the airbag inflator assembly. NOTE: The studs on the airbag cushion are offset to prevent incorrect installation. 15. Place the airbag inflator bracket into position (Figure 7). 16. Install the airbag cushion retaining nuts. Tighten the nuts to 55 in. lbs (6 N.m) in the sequence shown in Figure 9. 17. Install the airbag plastic door/cover. 18. Install the airbag assembly into the instrument panel opening. CAUTION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6618 Be certain that the rear edge of the passenger airbag lower bracket is engaged in the hook formation of the instrument panel airbag support bracket or retaining bolt misalignment can occur. 19. Install the airbag inflator bracket retaining bolts and tighten to 55 in.lbs. (6 N.m). 20. Connect the yellow airbag connector to instrument panel harness and slide the red CPA lock into the locked position. 21. Install the glove box assembly. 22. Connect the StarSCAN scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. NOTE: Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. 23. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. 24. Check to be certain that no one is in the vehicle, then reconnect the negative battery cable. 25. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. 26. Power up the StarSCAN tool. 27. Connect the StarSCAN to the internet. 28. From the "HOME" screen select "Flash Download". 29. Select "Download Files from DealerCONNECT" and press the "Next" button. 30. Select "OK". 31. Enter logon data requested by the StarSCAN and press the "OK" button. 32. Select "Read Information from Connected Vehicle" and then press the "Next" button. 33. Press the "Finish" button for search results. 34. Select "ORC" file and press "Download to Scan Tool" button. 35. Press the "Close" button after the download is complete. 36. Press the "Show Shortcuts" button. 37. Press the "Home" button. 38. Select "ECU View" button. 39. Select "ORC" from the list. 40. Select "More Options" button. 41. Select "ECU Flash" button. 42. Select the "ORC" flash file. 43. Select "Update Controller" button and follow the screen prompts to reprogram the ORC module. 44. After the reprogramming is complete, press the "Show Shortcuts" button. 45. Press the "Home" button. 46. From the "Home" screen select "System View". 47. Select "All DTC's" button. 48. Select "Clear All Stored DTC's" button and follow the screen prompts to clear codes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Recalls: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6619 49. After all codes are cleared, turn the ignition key to the "Off" position and disconnect the StarSCAN from the vehicle. 50. Turn off and disconnect the battery charger. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-001-07B > May > 07 > Air Bag System - Passenger Air Bag Deactivation Air Bag: All Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-001-07B > May > 07 > Air Bag System - Passenger Air Bag Deactivation > Page 6625 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > 08-001-07B > May > 07 > Air Bag System - Passenger Air Bag Deactivation > Page 6626 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag: All Technical Service Bulletins Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement Technical Service Bulletin # F40 Date: 060901 Recall - Passenger Air Bag Cushion Replacement September 2006 Dealer Service Instructions for: Safety Recall F40 Passenger Airbag Cushion Models 2006 (DR) Dodge Ram Pick up Truck (1500 Series) NOTE: This recall applies only to the above vehicles built with Advanced Multistage Front Airbags (sales code CG3). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The passenger airbag on about 144,000 of the above vehicles may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. This can increase the risk of injury to a child seat occupant during certain crash conditions. As a result, these vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 208 Occupant Crash Protection. Repair The passenger airbag cushion must be replaced and the Occupant Restraint Controller (ORC) must be reprogrammed (flashed). NOTE: The owner notification for this recall will be delayed until an adequate quantity of parts is available. Parts Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6635 Special Tools Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6636 vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Disconnect and isolate the negative battery cable. Wait two minutes for the system capacitor to discharge before further service. WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before replacing the passenger airbag cushion. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. 2. Using a plastic trim stick, remove the windshield trim bezel from the instrument panel. 3. Remove the glove box assembly from the instrument panel by squeezing the sides inward and rolling the door downward (Figure 1) 4. Disengage the airbag inflator pigtail wire connector from the plastic push-in retainer plate on the right side of the instrument panel airbag support bracket by: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6637 a. Using a small screwdriver, carefully pry the leading edge of the push-in retainer plate away from the connector insulator far enough to clear the engagement tab on the insulator (Figure 2). b. Pull the connector toward you to slide it off of the push-in retainer plate. 5. Disconnect the instrument panel wire harness connector from the yellow airbag inflator pigtail wire connector on the right side of the instrument panel airbag support bracket (Figure 3). To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 6. Remove the two airbag module mounting bolts that secure the passenger airbag lower bracket to the instrument panel airbag support bracket (Figure 3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6638 7. Using a plastic trim stick, gently pry on the outboard edges of the passenger airbag door/cover to disengage the snap features from the receptacles in the instrument panel (Figure 4). 8. Remove the passenger airbag assembly from the instrument panel. 9. Mount the airbag assembly in a bench vise as shown in Figure 5. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6639 10. Remove the airbag plastic door/cover by rolling the cover off the retaining fingers (Figure 6). 11. Remove and save the four airbag cushion retaining nuts (Figure 7). 12. Remove the inflator bracket (Figure 7). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6640 13. Carefully remove the airbag cushion from the inflator assembly (Figure 8). 14. Install the new airbag cushion into the airbag inflator assembly. NOTE: The studs on the airbag cushion are offset to prevent incorrect installation. 15. Place the airbag inflator bracket into position (Figure 7). 16. Install the airbag cushion retaining nuts. Tighten the nuts to 55 in. lbs (6 N.m) in the sequence shown in Figure 9. 17. Install the airbag plastic door/cover. 18. Install the airbag assembly into the instrument panel opening. CAUTION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6641 Be certain that the rear edge of the passenger airbag lower bracket is engaged in the hook formation of the instrument panel airbag support bracket or retaining bolt misalignment can occur. 19. Install the airbag inflator bracket retaining bolts and tighten to 55 in.lbs. (6 N.m). 20. Connect the yellow airbag connector to instrument panel harness and slide the red CPA lock into the locked position. 21. Install the glove box assembly. 22. Connect the StarSCAN scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. NOTE: Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. 23. Turn the ignition switch to the "ON" position and exit the vehicle with the scan tool. 24. Check to be certain that no one is in the vehicle, then reconnect the negative battery cable. 25. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. 26. Power up the StarSCAN tool. 27. Connect the StarSCAN to the internet. 28. From the "HOME" screen select "Flash Download". 29. Select "Download Files from DealerCONNECT" and press the "Next" button. 30. Select "OK". 31. Enter logon data requested by the StarSCAN and press the "OK" button. 32. Select "Read Information from Connected Vehicle" and then press the "Next" button. 33. Press the "Finish" button for search results. 34. Select "ORC" file and press "Download to Scan Tool" button. 35. Press the "Close" button after the download is complete. 36. Press the "Show Shortcuts" button. 37. Press the "Home" button. 38. Select "ECU View" button. 39. Select "ORC" from the list. 40. Select "More Options" button. 41. Select "ECU Flash" button. 42. Select the "ORC" flash file. 43. Select "Update Controller" button and follow the screen prompts to reprogram the ORC module. 44. After the reprogramming is complete, press the "Show Shortcuts" button. 45. Press the "Home" button. 46. From the "Home" screen select "System View". 47. Select "All DTC's" button. 48. Select "Clear All Stored DTC's" button and follow the screen prompts to clear codes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag: > F40 > Sep > 06 > Recall - Passenger Air Bag Cushion Replacement > Page 6642 49. After all codes are cleared, turn the ignition key to the "Off" position and disconnect the StarSCAN from the vehicle. 50. Turn off and disconnect the battery charger. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-001-07B > May > 07 > Air Bag System - Passenger Air Bag Deactivation Air Bag: All Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-001-07B > May > 07 > Air Bag System - Passenger Air Bag Deactivation > Page 6648 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag: > 08-001-07B > May > 07 > Air Bag System - Passenger Air Bag Deactivation > Page 6649 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 6650 Air Bag: Diagrams Airbag - Passenger Squib Airbag Side Curtain - Left Airbag Side Curtain - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain Air Bag: Description and Operation Air Bag-Side Curtain Optional side curtain airbags are available for this model when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the "SRS - AIRBAG" logo located on the headliner above each A-pillar (standard cab), or above each B-pillar (quad cab and mega cab). This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails (5). Each folded airbag cushion is contained within a fabric wrap (8) that extends along the roof rail from the A-pillar (6) at the front of the vehicle to the pillar at the rear of the vehicle. The channel is initially secured during installation with plastic push-in fasteners to the roof rail. A long tether (7) extends down the A-pillar from the front of the airbag cushion, where it is retained to the pillar with plastic push-in routing clips and it is secured to the base of the A-pillar near the belt line with a screw. Mega cab models also hale a rear tether that is retained with plastic push-in routing clips and secured to the C-pillar near the back of the cab with a screw. The hybrid-type inflator (3) for each airbag is secured to the roof rail at the rear of the airbag unit behind the B-pillar (standard cab) or C-pillar (quad cab and mega cab), and is connected to the airbag cushion by a long tubular manifold (4). The entire assembly is secured to several spring nuts spaced along the inside of the roof rail with screws. A two-wire take out and connector of the body wire harness with a keyed and latched connector insulator (1) on the B-pillar (standard cab) or C-pillar (quad cab and mega cab) is connected directly to the connector receptacle of the initiator near the back of the airbag inflator. The body wire harness connects each curtain airbag unit to the Occupant Restraint Controller (ORC). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, faulty, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, and C-pillar trim, and all other visibly damaged components must be replaced. Each side curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6653 chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision. The front tethers keep the front portion of the side airbag cushion taut to the side, as does the rear tether for the rear portion of the cushion on mega cab models, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion quickly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6654 Air Bag: Description and Operation Air Bag-Driver The color-keyed, injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the armature of the four-spoke steering wheel. All models have a chrome Dodge Ram emblem in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The airbag cushion, housing (5), and inflator (3) are secured within an integral receptacle molded into the back of the trim cover (4). The four vertical walls of this receptacle have a total of twelve small windows with blocking tabs that are engaged by twelve hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver airbag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire has an eyelet terminal connector that is captured beneath a flanged nut on the upper right inflator mounting stud on the back of the housing. The horn switch feed pigtail wire has a black, molded plastic insulator (1) that is secured by an integral retainer in a locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out and connector of the steering wheel wire harness. Both horn switch wires are routed through an integral notch in the center of the upper edge of the airbag housing stamping. The airbag used in this model is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. A 71 centimeter (28 inch) diameter, radial deploying fabric cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic type unit with four mounting studs and is secured to the stamped metal airbag housing by four flanged hex nuts. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag unit cannot be repaired, and must be replaced if deployed or in any way damaged. The driver airbag trim cover and horn switch unit Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6655 may be disassembled from the driver airbag unit, and is available for separate service replacement. The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6656 Air Bag: Description and Operation Air Bag-Passenger The horizontal surface of the injection molded, thermoplastic passenger airbag door (1) is the most visible part of the passenger airbag. The passenger airbag door is located above the glove box opening on the top of the instrument panel (2) in front of the front seat passenger seating position. The forward and outboard edges of the airbag door are secured with integral snap features (3) to the instrument panel base trim, while the rearward edge has several interlocking tabs that engage slots in the base trim. Located below the passenger airbag door (2) within the instrument panel is the passenger airbag unit. The passenger airbag unit is secured by two screws through a stamped mounting bracket (5) to a support bracket welded onto the instrument panel structural support. The passenger airbag housing fits into a molded receptacle on the back of the airbag door, where several stamped hook formations on the forward and rearward edges of the airbag housing are engaged in mating small window openings on the forward and rearward flanges of the receptacle to secure the airbag door to the airbag housing. These airbag door fasteners and mounting provisions are all concealed beneath the instrument panel base trim. The passenger airbag unit used in this model is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior models. The passenger airbag unit consists of a stamped and welded metal housing, the airbag cushion, the airbag inflator, and a stamped metal airbag cushion retainer plate that is secured to the airbag housing with four studs and nuts. The airbag housing contains the airbag inflator and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion is used. The airbag inflator (4) is a non-azide, pyrotechnic-type unit that is secured to and sealed within the airbag housing. A short four-wire pigtail harness with a keyed, yellow connector insulator (1) connects the two inflator initiators to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The passenger airbag includes the airbag door. This unit cannot be repaired, and must be replaced if deployed, faulty, or in any way damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Air Bag-Side Curtain > Page 6657 The multistage passenger airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the passenger airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through a vent hole in each fabric side panel of the airbag cushion. Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status Air Bag: Service and Repair Airbag Squib Status Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this model are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used due to an airbag system fault; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are sure of complete deployment. Refer to the Hazardous Substance Control System for proper disposal procedures. Dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local, and federal regulations. 1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. 2. Turn the ignition switch to the On position. 3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. Airbag Squib Status (Part 1) Airbag Squib Status (Part 2) Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver and/or passenger airbag squibs. NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the squibs were both live. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6660 Air Bag: Service and Repair Cleanup Procedure Following a supplemental restraint deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a supplemental restraint. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: TO AVOID PERSONAL INJURY OR DEATH, IF YOU EXPERIENCE SKIN IRRITATION DURING CLEANUP, RUN COOL WATER OVER THE AFFECTED AREA. ALSO, IF YOU EXPERIENCE IRRITATION OF THE NOSE OR THROAT, EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES. IF IRRITATION CONTINUES, SEE A PHYSICIAN. 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are sure of complete deployment. Refer to "AIRBAG SQUIB STATUS" . See: Airbag Squib Status All damaged, faulty, or non-deployed supplemental restraints which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is faulty or damaged and non-deployed, refer to the Hazardous Substance Control System for proper disposal. Be certain to dispose of all non-deployed and deployed supplemental restraints in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed supplemental restraints from the vehicle. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6661 Air Bag: Service and Repair Air Bag-Side Curtain WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE SIDE CURTAIN AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE SIDE CURTAIN AIRBAG CUSHION AND THE HEADLINER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. NOTE: The following procedure is for replacement of a faulty or damaged side curtain airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the headliner from the vehicle. 3. On mega cab models only, remove the screw and disengage the two retainers that secure the side curtain airbag rear tether to the inner C-pillar near the cab back panel. 4. Remove the screw (6) that secures the side curtain airbag front tether retainer (5) to the base of the A-pillar near the belt line. 5. Disengage the two side curtain airbag front tether plastic retainer clips (4) from the A-pillar. 6. Disconnect the body wire harness connector (9) for the side curtain airbag from the connector receptacle at the back of the inflator. 7. Working from front to rear, remove the four (standard cab), five (quad cab) or eight (mega cab) screws (3) that secure the side curtain airbag inflator and manifold tube brackets to the spring nuts (2) in the roof rail (1). 8. Disengage the three (standard cab), four (quad cab) or six (mega cab) plastic push-in fasteners (8) that secure the side curtain airbag to the roof rail. 9. Remove the side curtain airbag (7) from the vehicle as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6662 1. Check to be certain that the four (standard cab), six (quad cab) or eight (mega cab) spring nuts (2) are properly installed in the inner roof rail (1) and that they are in good condition. 2. Position the side curtain airbag (7) into the vehicle as a unit. 3. Working from rear to front, align each of the three (standard cab), four (quad cab) or six (mega cab) plastic push-in fasteners (8) on the side curtain airbag with their holes in the inner roof side rail and push them straight in until they are fully seated. 4. Working from rear to front, install and tighten the four (standard cab), five (quad cab) or eight (mega cab) screws (3) that secure the side curtain airbag to the spring nuts in the inner roof rail. Tighten the screws to 6 N.m (50 in. lbs.). 5. Reconnect the body wire harness connector (9) for the side curtain airbag to the connector receptacle at the back of the inflator. Be certain that the connector is fully engaged and latched. 6. Engage the two plastic retainer clips (4) that secure the side curtain airbag front tether to the inner A-pillar. 7. Install and tighten the screw (6) that secures the front tether retainer (5) to the base of the A-pillar near the belt line. Tighten the screw to 6 N.m (55 in. lbs.). 8. On mega cab models only, engage the two retainer clips that secure the side curtain airbag rear tether to the inner C-pillar near the cab back panel. 9. On mega cab models only, install and tighten the screw that secures the rear tether retainer to the inner C-pillar near the cab back panel. Tighten the screw to 6 N.m (55 in. lbs.). 10. Reinstall the headliner into the vehicle. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6663 Air Bag: Service and Repair Air Bag-Driver Removal and Installation REMOVAL WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG CUSHION AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. NOTE: The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. 1. Disconnect and isolate the battery negative cable. Wait two minutesfor the system capacitor to discharge before further service. 2. From the underside of the steering wheel, remove the two screws (3) that secure the driver airbag (1) to the steering wheel armature (2). CAUTION: Do not pull on the horn switch feed pigtail wire to disengage the connector from the driver airbag housing or to disconnect the horn switch to steering wheel wire harness connection. Improper pulling on this pigtail wire or connection can result in damage to the horn switch membrane or feed circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6664 3. Pull the driver airbag (1) away from the steering wheel far enough to access the three electrical connections on the back of the airbag housing. 4. Disconnect the steering wheel wire harness connector for the horn switch (2) from the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle. Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators. 5. The clockspring driver airbag pigtail wire connectors (3) are secured by integral latches to the airbag inflator connector receptacles, which are located on the back of the driver airbag housing. Depress the latches on each side of the connector insulator and pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles. 6. Remove the driver airbag from the steering wheel. 7. If the driver airbag has been deployed, the clockspring must be replaced. INSTALLATION WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT AIRBAGS ARE SERVICED WITH TRIM COVERS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. NOTE: The following procedure is for replacement of a faulty or damaged driver airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6665 1. Position the driver airbag (1) close enough to the steering wheel to reconnect the three electrical connections on the back of the airbag housing. 2. When installing the driver airbag, reconnect the two clockspring driver airbag pigtail wire connectors (3) to the airbag inflator connector receptacles by pressing straight in on the connector. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. You can be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place. 3. Reconnect the steering wheel wire harness connector (2) for the horn switch to the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. 4. Carefully position the driver airbag (1) in the steering wheel (2). Be certain that the clockspring pigtail wires and the steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel armature. 5. From the underside of the steering wheel, install and tighten the two screws (3) that secure the driver airbag to the steering wheel armature. Tighten the screws to 10 N.m (90 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Disassembly and Assembly DISASSEMBLY WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6666 THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLER-CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver airbag from the steering wheel. 3. Place the driver airbag on a suitable clean and dry work surface with the trim cover facing down. If the trim cover will be reused, be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 4. Carefully pry the horn switch feed pigtail wire connector (1) away from the back of the driver airbag housing (3) far enough to disengage the integral connector retainer from the locator hole just above the upper right inflator mounting stud. 5. Remove the nut that secures the horn switch ground pigtail wire eyelet terminal (2) to the upper right inflator stud on the back of the driver airbag housing. 6. Remove the horn switch ground pigtail wire eyelet terminal from the upper right inflator stud on the back of the driver airbag housing. 7. Disengage each of the twelve hooks (5 and 6) of the airbag housing from the twelve windows in the vertical walls of the trim cover (4), one wall at a time. Start by disengaging the upper wall, then do each of the two side walls,and finish with the lower wall. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag housing firmly and evenly downward into the trim cover receptacle, while at the same time pushing outward on the upper edge of the receptacle wall. 8. With all of the hooks disengaged, lift the housing, inflator, and cushion as a unit from the receptacle on the back of the driver airbag trim cover. ASSEMBLY WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, SERVICE OF THIS UNIT SHOULD BE PERFORMED ONLY BY DAIMLER-CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJURIES. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6667 ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE DRIVER AIRBAG CUSHION AND THE DRIVER AIRBAG TRIM COVER. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE DRIVER AIRBAG TRIM COVER MUST NEVER BE PAINTED. REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is faulty or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. 1. Place the driver airbag on a suitable work surface with the airbag cushion facing up. 2. Fold the two flaps (1) of cushion material up around the sides and over the top of the airbag cushion retainer strap (2). 3. Position the new driver airbag trim cover over the airbag cushion, then push the receptacle of the trim cover down evenly over the cushion. Be certain that the cushion material flaps remain oriented over the cushion retainer strap as they were in Step 2. 4. Turn the driver airbag and the new driver airbag trim cover over as a unit, and place the unit on a suitable clean and dry work surface with the airbag cushion facing down. Be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 5. Be certain that the horn switch feed and ground pigtail wires are routed through the clearance notch at the top of the airbag housing (3), between the housing and the upper vertical wall of the trim cover receptacle. 6. Work around the perimeter of the unit engaging each of the twelve hooks (5 and 6) on the driver airbag housing through the windows in the walls of the trim cover receptacle. 7. Install the horn switch ground pigtail wire eyelet terminal (2) over the upper right inflator stud on the back of the driver airbag housing. 8. Install and tighten the nut that secures the horn switch ground pigtail wire eyelet terminal to the upper right inflator stud on the back of the driver airbag housing. Tighten the nut to 7 N.m (65 in. lbs.). 9. Using hand pressure, push the integral retainer of the horn switch feed pigtail wire connector (1) into the locator hole just above the upper right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6668 inflator mounting stud on the back of the airbag housing. 10. After the driver airbag has been assembled, try pulling the trim cover and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks. 11. Before reinstalling the airbag onto the steering wheel, check that the blocking tab (1) in each of the trim cover windows is oriented over the airbag housing hook (4) as shown. 12. Reinstall the driver airbag onto the steering wheel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6669 Air Bag: Service and Repair Air Bag-Passenger NOTE: The following procedure is for replacement of a faulty or damaged passenger airbag. If the airbag is faulty or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. REMOVAL WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, WHEN REMOVING A DEPLOYED AIRBAG, RUBBER GLOVES, EYE PROTECTION, AND A LONG-SLEEVED SHIRT SHOULD BE WORN. THERE MAY BE DEPOSITS ON THE AIRBAG UNIT AND OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the top cover from the top of the instrument panel. 3. Remove the glove box from the instrument panel. 4. Reach up into the instrument panel between the upper glove box opening reinforcement and the cross car beam (4) to access and disconnect the instrument panel wire harness connector (2) from the airbag inflator pigtail wire connector on the right side of the instrument panel airbag support bracket. To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 5. Remove the two screws (3) that secure the passenger airbag lower bracket to the instrument panel airbag support bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6670 6. Disengage the airbag inflator pigtail wire connector (1) from the plastic push-in retainer plate (3) on the right side of the instrument panel airbag support bracket. To disengage the connector: a. Using a small screwdriver (4), carefully pry the leading edge of the push-in retainer plate away from the connector insulator far enough to clear the engagement tab (2) on the insulator. b. Pull the connector toward you to slide it off of the push-in retainer plate. 7. Using a trim stick (2) or another suitable wide flatbladed tool, gently pry the forward, then the outboard edges of the passenger airbag door (1) away from the instrument panel (3) far enough to disengage the snap features on the door from the receptacles in the instrument panel base trim. 8. Remove the passenger airbag and airbag door from the instrument panel as a unit. INSTALLATION WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PASSENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, THE PASSENGER AIRBAG DOOR MUST NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG UNITS ARE SERVICED WITH DOORS IN THE ORIGINAL COLORS. PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE AIRBAG DOOR RESPONDS TO AN AIRBAG DEPLOYMENT. FAILURE TO OBSERVE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Airbag Squib Status > Page 6671 THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. 1. Carefully position the passenger airbag and airbag door through the opening in the top of the instrument panel base trim as a unit. Be certain that the rear edge of the passenger airbag lower bracket is engaged in the hook formation (5) of the instrument panel airbag support bracket, and the anti-rotation tabs (1) on either side of the hook are engaged in the two holes in the airbag lower bracket. 2. Install and tighten the two screws (3) that secure the passenger airbag lower bracket to the instrument panel airbag support bracket. Tighten the screws to 6 N.m (55 in. lbs.). 3. Slide the airbag inflator pigtail wire connector onto the plastic push-in retainer plate on the right side of the instrument panel airbag support bracket far enough snap it into place over the engagement tab on the connector insulator. 4. Reconnect the instrument panel wire harness connector to the passenger airbag pigtail wire connector on the right side of the airbag lower mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. 5. Engage the interlocking tabs on the rear edge of the passenger airbag door into the corresponding slots in the instrument panel base trim. 6. Using hand pressure, push down on the passenger airbag door over each snap feature on both sides and the forward edge of the airbag door until it snaps into its receptacle in the instrument panel base trim. 7. Reinstall the glove box into the instrument panel. 8. Reinstall the top cover onto the top of the instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag Control Module: Recalls Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag Control Module: All Technical Service Bulletins Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6685 Air Bag Control Module: Locations Front Center Body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6686 Left Side Body - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6687 Left Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6688 Air Bag Control Module: Diagrams Module - Occupant Restraint Controller C1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6689 Module - Occupant Restraint Controller C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6693 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6694 Switch - Passenger Airbag On/Off Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6695 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The "Off" position nomenclature of the switch is illuminated and visible only when that switch position is selected. The "On" position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off nomenclature), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the Off indicator will be extinguished and the passenger airbag is enabled. The Off indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ORC provides a ground input to the Off indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ORC, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6696 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: A passenger airbag on/off switch is used only on standard cab models equipped with dual front airbags. Quad cab and mega cab models have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6697 following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Clockspring C4 (Premium) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6701 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring assembly is secured with two screws onto the multi-function switch mounting housing near the top of the steering column behind the steering wheel. The clockspring consists of a flat, round molded plastic case (8) with a stubby tail that hangs below the steering column. The tail contains two connector receptacles that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor (10) with a large exposed hub. The upper surface of the rotor hub has a large center hole, two large flats, an engagement dowel with a yellow rubber boot (7), two short pigtail wires with connectors (1), and two connector receptacles (5) that face toward the steering wheel. The lower surface of the rotor hub has a molded plastic turn signal cancel cam (3) with two lobes that is keyed to the rotor and is secured there with four integral snap features. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles (4) that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that face the steering wheel. Service replacement clocksprings are shipped pre-centered and with a molded plastic locking pin (1) that snaps into a receptacle on the rotor and is engaged between two tabs on the upper surface of the rotor case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed from the clockspring after it is installed on the steering column. The clockspring cannot be repaired. If the clockspring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this model the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches, if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate contact noise between the dowel and the steering wheel. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. Two short, yellow-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the multistage driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch feed pigtail wire Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6702 connector and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6703 Clockspring Assembly / Spiral Cable: Adjustments WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. 3. Rotate the clockspring rotor (10) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel and yellow rubber boot (7) should end up at the bottom, and the arrows on the clockspring rotor and case (9) should be in alignment. 5. The clockspring is now centered. Secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. 6. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6704 Clockspring Assembly / Spiral Cable: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight ahead position. 2. Disconnect and isolate the battery negative cable. 3. Remove the driver airbag from the steering wheel. 4. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Remove the steering wheel from the steering column. 6. Remove the steering column opening cover from the instrument panel. 7. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 8. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 9. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6705 secure the two shroud halves to each other. 10. Remove the upper shroud from the lower shroud and the steering column. 11. Remove the one center screw that secures the lower shroud to the steering column (4). 12. Remove the lower shroud from the steering column. 13. Disconnect the two instrument panel wire harness connectors from the two connector receptacles located below the steering column on the back of the clockspring housing. 14. Remove the two screws (3) that secure the clockspring to the multi-function switch mounting housing. 15. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver airbag has been deployed. 16. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. INSTALLATION CAUTION: If the clockspring is not properly centered in relation to the steering wheel, steering shaft and steering gear, it may be damaged. Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6706 1. While holding the centered clockspring rotor and case stationary in relation to each other, carefully slide the clockspring down over the steering column upper shaft. 2. Align and seat the hole in the locating tab (2) on the clockspring case over the locating pin on the multi-function switch mounting housing. 3. Install and tighten the two screws (3) that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 N.m (20 in. lbs.). 4. Reconnect the two instrument panel wire harness connectors to the two connector receptacles located below the steering column on the back of the clockspring housing. 5. Position the lower shroud (3) onto the steering column (4). 6. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 7. Position the upper shroud (1) onto the steering column over the lower shroud. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 8. Align the snap features on the upper shroud with the receptacles on the lower shroud and apply hand pressure to snap them together. 9. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 10. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 11. Reinstall the steering column opening cover onto the instrument panel. 12. If a new clockspring has been installed, remove the plastic locking pin that is securing the clockspring rotor to the clockspring case to maintain clockspring centering. NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 13. Reinstall the steering wheel onto the steering column. 14. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 6707 harness is routed between the steering wheel back trim cover and the steering wheel armature. 15. Reinstall the driver airbag onto the steering wheel. 16. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6711 Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6712 Left Side Body - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6713 Standard Cab Right Side Body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6714 Left Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6715 Right Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6716 Impact Sensor: Diagrams Sensor-Front Impact - Left Sensor-Front Impact - Right Sensor-Side Impact - Left 1 Sensor-Side Impact - Right 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6717 Impact Sensor: Description and Operation FRONT Two front impact sensors (1) are used on this model, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires the use of a diagnostic scan tool. Refer to Trouble Code Diagnostic Charts. SIDE Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain airbags, one each for the left and right sides of the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 6718 vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Occupant Restraint Controller (ORC). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires the use of a diagnostic scan tool. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE FRONT IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. INSTALLATION 1. Position the right or left front impact sensor (3) into the engine compartment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6721 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 N.m (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6722 Impact Sensor: Service and Repair Side WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. SIDE - STANDARD CAB REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6723 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. SIDE - QUAD CAB REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6724 INSTALLATION 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. SIDE - MEGA CAB REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6725 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation An airbag indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the airbag system, which is not available in some markets. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The airbag indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Airbag in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The airbag indicator is serviced as a unit with the instrument cluster. The airbag indicator gives an indication to the vehicle operator when the airbag system is faulty or inoperative. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Occupant Restraint Controller (ORC) over the Controller Area Network (CAN) data bus. The airbag indicator gives an indication to the vehicle operator when the airbag system is faulty or inoperative. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Occupant Restraint Controller (ORC) over the Controller Area Network (CAN) data bus. - Bulb Test - Each time the ignition switch is turned to the ON position the airbag indicator is illuminated for about six to eight seconds. The entire bulb test is a function of the ORC. - ORC Lamp-On Message - Each time the cluster receives a lamp-on message from the ORC, the airbag indicator will be illuminated. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-off message from the ORC, whichever is longer. This indicator will also be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no airbag messages for 10 consecutive message cycles, the airbag indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the ORC. - Actuator Test - Each time the cluster is put through the actuator test, the airbag indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the airbag indicator is a function of the instrument cluster. The ORC continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ORC then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the ORC sends a lamp-on message after the bulb test, it indicates that the ORC has detected a system malfunction and/or that the airbags and seat belt tensioners may not deploy when required, or may deploy when not required. The ORC will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ORC of the condition, the instrument cluster and the ORC will each store a DTC, and the cluster will flash the seatbelt indicator on and off as a backup to notify the vehicle operator. For proper diagnosis of the airbag system, the ORC, the CAN data bus, or the electronic message inputs to the instrument cluster that control the airbag indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls for Air Bag Control Module: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag Control Module: Recalls Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA06V353000 > Sep > 06 > Recall 06V353000: Passenger Air Bag Replacement Air Bag Control Module: All Technical Service Bulletins Recall 06V353000: Passenger Air Bag Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V353000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Air Bags: Frontal POTENTIAL NUMBER OF UNITS AFFECTED: 144750 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, "Occupant Crash Protection." The passenger air bag may deploy with excessive force when certain model rear facing child seats are installed in the right front passenger seat position. CONSEQUENCE: This can increase the risk of injury to a child seat occupant during certain crash conditions. REMEDY: Dealers will replace the passenger air bag cushion and reprogram the occupant restraint controller. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F40. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6743 Air Bag Control Module: Locations Front Center Body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6744 Left Side Body - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6745 Left Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6746 Air Bag Control Module: Diagrams Module - Occupant Restraint Controller C1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 6747 Module - Occupant Restraint Controller C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 6753 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 6754 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation This model is equipped with a Lower Anchors and Tether for Children, or LATCH child restraint anchorage system. The LATCH system provides for the installation of suitable child restraints in certain seating positions without using the standard equipment seat belt provided for that seating position. Standard cab models are equipped with a fixed-position child restraint upper tether anchor for the front center and outboard seating positions (2), and child restraint lower anchors for the front outboard seating position (1). Quad cab models are equipped with a fixed-position child restraint upper tether anchor strap for the rear center and both rear outboard seating positions (2), and child restraint lower anchors for both rear outboard seating positions (1). All front seat child restraint anchors are deleted on quad cab models. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6759 Mega cab models are also equipped with a fixed-position child restraint upper tether anchor strap for the rear center and both rear outboard seating positions (2), but have child restraint lower anchors for all three rear seating positions (1). As on quad cab models, all front seat child restraint anchors are deleted on mega cab models. The two upper tether anchors (3) for standard cab models are integral to the upper cab back panel reinforcement and are concealed behind individual trim cover and bezel units (1) that are integral to the cab back trim panel (2). These upper tether anchors cannot be adjusted or repaired and, if faulty or damaged, they must be replaced as a unit with the upper cab back panel reinforcement. The upper tether anchor trim covers and bezels are serviced as a unit with the cab back trim panel. The three upper tether anchor straps (1) for quad cab and mega cab models are secured to the upper cab back panel (2) reinforcement with screws (3). These anchor straps are concealed behind the upright rear seat back. The upper tether anchor straps are available for individual service replacement. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6760 The lower anchors (2) for all models are integral to their respective front or rear seat cushion frame. Round markers (3) with an imprinted child seat icon on the standard cab front seat back trim cover helps identify the anchor locations for that application because they may be otherwise difficult to see with the seat back in the upright position. These lower anchors are each constructed from round steel bar stock that is formed into a U-shape, then securely welded at each end to the seat cushion frame. They are each accessed from the front of their respective seats, at each side where the seat back meets the seat cushion. These lower anchors cannot be adjusted or repaired and, if faulty or damaged, they must be replaced as a unit with the seat cushion frame. On quad cab or mega cab models, if the rear seat lower anchors (2) have been bent or broken as a result of a vehicle collision, the latch for the affected rear seat cushion frame unit must also be replaced. See the vehicle glove box for more information on the proper use of all of the factory-installed child restraint anchors. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 6761 Child Seat Tether Attachment: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: The following procedure applies only to the rear seat upper child tether straps used on quad cab models. The child restraint anchors used in other models and locations are integral to other components and cannot be serviced separately. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (3) that secures the child tether strap (1) to the upper cab back panel (2) reinforcement. 3. Remove the child tether strap from the upper cab back panel reinforcement. INSTALLATION 1. Position the child tether strap (1) onto the cab back panel (2) upper reinforcement. 2. Install and tighten the screw (3) that secures the child tether strap to the upper cab back panel reinforcement. Tighten the screw to 14 N.m (10 ft. lbs.). 3. Reinstall the rear seat into the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > NHTSA06V354000 > Sep > 06 > Recall 06V354000: Passenger Seat Belt Replacement Seat Belt: Recalls Recall 06V354000: Passenger Seat Belt Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V354000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Seat Belts: Front POTENTIAL NUMBER OF UNITS AFFECTED: 159741 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, 'Occupant Crash Protection.' The front passenger seat belt may not be able to tighten securely on certain model child seats. CONSEQUENCE: This can increase the risk of injury to a child seat occupant in the event of a crash. REMEDY: Dealers will replace the front passenger seat belt. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall No. F41. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement Technical Service Bulletin # F41 Date: 060901 Recall - Passenger Seat Belt Replacement September 2006 Dealer Service Instructions for: Safety Recall F41 Front Passenger Seat Belt Models 2006 (DR) Dodge Ram Pick Up Truck (1500 Series) NOTE: This recall applies only to the above vehicles built at the St. Louis North Assembly Plant ("J" in the 11th VIN Position) with sales code XZ9 and all of the above vehicles built at the Saltillo Assembly Plant ("G" in the 11th VIN Position) and Warren Assembly Plant ("S" in the 11th VIN Position). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front passenger seat belt on about 159,000 of the above vehicles may not be able to tightly secure certain model child seats. This can increase the risk of injury to a child seat occupant during certain crash conditions. As a result, these vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 208 - Occupant Crash Protection. Repair The front passenger seat belt must be replaced. NOTE: The owner notification for this recall will be delayed until an adequate supply of parts is available. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6774 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6775 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Move the passenger seat to the full forward position on quad cab models and move both seats full forward on standard cab models. 2. Open the hood and disconnect the negative battery cable. 3. For QUAD cab vehicles only, remove the grab handle from the "B" pillar. 4. For Standard cab vehicles only, remove the rear storage tray. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6776 5. Remove and discard the turning loop cover (Figure 1). 6. Remove the turning loop retaining bolt (Figure 1). 7. Remove the upper trim cover (Figure 1). 8. Carefully remove the seat belt seat anchor cover (Figure 2). 9. Remove the seat belt anchor plate bolt from the seat (Figure 2). 10. Partially remove the sill plate(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6777 11. Remove the lower trim cover to expose the seat belt retractor (Figure 3). 12. Remove the plastic seat belt guide from the "B" pillar (Figure 3). 13. Disconnect the electrical connector at the seat belt retractor (Figure 3). NOTE: The connector has a yellow locking pin that has to be pulled out of the connector before removing the connector from the seat belt retractor. 14. Remove the upper and lower seat belt retractor retaining bolts (Figure 3). 15. Remove the seat belt retractor from the "B" pillar. 16. Place the new seat belt retractor into position. 17. Apply four to five drops of Mopar Lock & Seal thread locking compound (P/N 04318031) or equivalent to the threads and loosely install the lower retractor retaining bolt. 18. Install and tighten the upper seat belt retractor retaining bolt to 105 in. lbs. (12 N.m). 19. Tighten the lower seat belt retractor retaining bolt to 29 ft. lbs. (39 N.m). 20. Connect the electrical connector at the seat belt retractor (Figure 3). 21. Install the upper plastic seat belt guide onto the "B" pillar (Figure 3). 22. Install the lower trim cover (Figure 3). 23. Install the sill plate(s). 24. Place the seat belt anchor plate onto the seat. Apply three or four drops of Mopar Lock & Seal thread locking compound (P/N 04318031) or equivalent to the retaining bolt threads and install the bolt. Tighten the seat belt anchor plate retaining bolt to 29 ft. lbs. (39 N.m). 25. Install the seat belt seat anchor cover (Figure 2). 26. Install the upper trim cover (Figure 1). 27. Apply three or four drops of Mopar Lock & Seal thread locking compound (P/N 04318031) or equivalent to the bolt threads and install the turning loop retaining bolt (Figure 1). Tighten the retaining bolt to 29 ft. lbs. (39 N.m). 28. Install the new turning loop cover provided with the seat belt (Figure 1). 29. For QUAD cab vehicles only, install the grab handle onto the "B" pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6778 30. For Standard cab vehicles only, install the rear storage tray. 31. Move seat back to its original position. 32. Connect the negative battery cable and close the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA06V354000 > Sep > 06 > Recall 06V354000: Passenger Seat Belt Replacement Seat Belt: All Technical Service Bulletins Recall 06V354000: Passenger Seat Belt Replacement MAKE/MODELS: MODEL/BUILD YEARS: Dodge/RAM 1500 2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V354000 MFG'S REPORT DATE: September 06, 2006 COMPONENT: Seat Belts: Front POTENTIAL NUMBER OF UNITS AFFECTED: 159741 SUMMARY: Certain pickup trucks fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 208, 'Occupant Crash Protection.' The front passenger seat belt may not be able to tighten securely on certain model child seats. CONSEQUENCE: This can increase the risk of injury to a child seat occupant in the event of a crash. REMEDY: Dealers will replace the front passenger seat belt. The recall is expected to begin during October 2006. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall No. F41. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement Technical Service Bulletin # F41 Date: 060901 Recall - Passenger Seat Belt Replacement September 2006 Dealer Service Instructions for: Safety Recall F41 Front Passenger Seat Belt Models 2006 (DR) Dodge Ram Pick Up Truck (1500 Series) NOTE: This recall applies only to the above vehicles built at the St. Louis North Assembly Plant ("J" in the 11th VIN Position) with sales code XZ9 and all of the above vehicles built at the Saltillo Assembly Plant ("G" in the 11th VIN Position) and Warren Assembly Plant ("S" in the 11th VIN Position). IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The front passenger seat belt on about 159,000 of the above vehicles may not be able to tightly secure certain model child seats. This can increase the risk of injury to a child seat occupant during certain crash conditions. As a result, these vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 208 - Occupant Crash Protection. Repair The front passenger seat belt must be replaced. NOTE: The owner notification for this recall will be delayed until an adequate supply of parts is available. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6788 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6789 Use the labor operation number and time allowance shown. Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Move the passenger seat to the full forward position on quad cab models and move both seats full forward on standard cab models. 2. Open the hood and disconnect the negative battery cable. 3. For QUAD cab vehicles only, remove the grab handle from the "B" pillar. 4. For Standard cab vehicles only, remove the rear storage tray. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6790 5. Remove and discard the turning loop cover (Figure 1). 6. Remove the turning loop retaining bolt (Figure 1). 7. Remove the upper trim cover (Figure 1). 8. Carefully remove the seat belt seat anchor cover (Figure 2). 9. Remove the seat belt anchor plate bolt from the seat (Figure 2). 10. Partially remove the sill plate(s). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6791 11. Remove the lower trim cover to expose the seat belt retractor (Figure 3). 12. Remove the plastic seat belt guide from the "B" pillar (Figure 3). 13. Disconnect the electrical connector at the seat belt retractor (Figure 3). NOTE: The connector has a yellow locking pin that has to be pulled out of the connector before removing the connector from the seat belt retractor. 14. Remove the upper and lower seat belt retractor retaining bolts (Figure 3). 15. Remove the seat belt retractor from the "B" pillar. 16. Place the new seat belt retractor into position. 17. Apply four to five drops of Mopar Lock & Seal thread locking compound (P/N 04318031) or equivalent to the threads and loosely install the lower retractor retaining bolt. 18. Install and tighten the upper seat belt retractor retaining bolt to 105 in. lbs. (12 N.m). 19. Tighten the lower seat belt retractor retaining bolt to 29 ft. lbs. (39 N.m). 20. Connect the electrical connector at the seat belt retractor (Figure 3). 21. Install the upper plastic seat belt guide onto the "B" pillar (Figure 3). 22. Install the lower trim cover (Figure 3). 23. Install the sill plate(s). 24. Place the seat belt anchor plate onto the seat. Apply three or four drops of Mopar Lock & Seal thread locking compound (P/N 04318031) or equivalent to the retaining bolt threads and install the bolt. Tighten the seat belt anchor plate retaining bolt to 29 ft. lbs. (39 N.m). 25. Install the seat belt seat anchor cover (Figure 2). 26. Install the upper trim cover (Figure 1). 27. Apply three or four drops of Mopar Lock & Seal thread locking compound (P/N 04318031) or equivalent to the bolt threads and install the turning loop retaining bolt (Figure 1). Tighten the retaining bolt to 29 ft. lbs. (39 N.m). 28. Install the new turning loop cover provided with the seat belt (Figure 1). 29. For QUAD cab vehicles only, install the grab handle onto the "B" pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > F41 > Sep > 06 > Recall - Passenger Seat Belt Replacement > Page 6792 30. For Standard cab vehicles only, install the rear storage tray. 31. Move seat back to its original position. 32. Connect the negative battery cable and close the hood. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 6793 Seat Belt: Description and Operation The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanisms for all seating positions except the driver's side front position are mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in any seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the seat belt and retractor unit and is concealed beneath a molded plastic cover located on one side of the retractor spool. The automatic locking mechanism cannot be adjusted or repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The locked mode of the automatic locking retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make a light, audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the light, audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt Seat Belt: Service and Repair Seat Belt WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab models have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab models. REMOVAL 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position and tilt the seat back forward for easiest access to the lower anchor of the front center seat belt buckle, lap belt or anchor buckle (1). 2. On standard cab models only, remove the stowage tray from the rear floor panel behind the seat. 3. From behind the front seat, remove the screw (5) that secures the lower anchor of the front center seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). 4. From the front of the front seat, reach between the side of the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the seat belt buckle, lap belt or anchor buckle through the elastic strap (2) on the side of the center seat cushion. 5. Remove the front center seat belt buckle, lap belt or anchor buckle unit from the front seat. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6796 1. From the front of the front seat, position the front center seat belt buckle, lap belt or anchor buckle unit (1) through the elastic strap (2) on the side of the center seat cushion (6). 2. From the front of the front seat, reach between the side of the center seat cushion and the adjacent right or left front outboard seat cushion to route the lower anchor of the seat belt buckle, lap belt or anchor buckle unit down between the side of the center seat cushion and the adjacent right or left front outboard seat cushion. Be certain that the belt webbing is not twisted. 3. From behind the front seat, position the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3).Be certain to engage the anti-rotation tab on the lower anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket. Tighten the screw to 40 N.m (29 ft. lbs.). 5. On standard cab models only, reinstall the stowage tray onto the rear floor panel behind the seat. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6797 Seat Belt: Service and Repair Seat Belt & Retractor Front Center WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flatbladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6798 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. INSTALLATION 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N.m (29 ft. lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 N.m (15 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6799 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - The following procedure is for replacement of a faulty or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. - The seat belt retractor on the driver's side of all standard cab models includes a tension reducer. All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6800 1. Adjust the front seat (1) to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 5. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 6. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 7. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 8. Remove the seat belt turning loop from the height adjuster. 9. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6801 10. Remove the lower trim (3) from the inside of the B-pillar. 11. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 12. On the driver side only, disconnect the white body wire harness connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor. 13. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 14. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 15. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 16. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 17. Remove the front outboard seat belt and retractor from the B-pillar as a unit. INSTALLATION 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 N.m (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. On the driver side only, reconnect the white body wire harness connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 8. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6802 9. Reinstall the upper trim (2) onto the inside of the B-pillar. 10. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 11. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 12. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 13. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 14. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 N.m (29 ft. lbs.). 15. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 16. Reinstall the stowage tray onto the rear floor panel behind the seat. 17. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Front Outboard - Quad and Mega Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6803 LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - The following procedure is for replacement of a faulty or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 4. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 5. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 6. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6804 9. Remove the lower trim (3) from the inside of the B-pillar. 10. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 11. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 12. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 13. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 14. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 15. Remove the front outboard seat belt and retractor from the B-pillar as a unit. INSTALLATION 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 N.m (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6805 8. Reinstall the upper trim (2) onto the inside of the B-pillar. 9. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 10. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 11. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 12. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 13. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 N.m (29 ft. lbs.). 14. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 15. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Rear Center - Quad Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The rear center seat belt and retractor is secured to a mounting bracket that includes the right outboard occupant seat belt buckle. The rear right outboard occupant buckle is available for service only as a unit with the center seat belt and retractor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6806 - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. 3. Remove the rear seat from the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 4. Lift upward on the forward edge of the rear center seat belt bezel (2) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket. 5. Remove the bezel from the webbing of the rear center seat belt. 6. Lift the rear center seat belt cover (3) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 7. Remove the two screws (4) that secure the belt bracket of the rear center seat belt to the body bracket on the upper cab back panel reinforcement. 8. Remove the belt bracket of the rear center seat belt from the body bracket. 9. Remove the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle (6) unit to the rear floor panel near the base of the cab back panel. 10. Remove the rear center seat belt and retractor unit from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6807 1. Position the rear center seat belt retractor and right outboard occupant buckle unit (6) onto the rear floor panel near the base of the cab back panel (1). 2. Loosely install the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle unit to the rear floor panel near the base of the cab back panel. 3. Position the belt bracket of the rear center seat belt onto the body bracket on the upper cab back panel reinforcement. 4. Install and tighten the two screws (4) that secure the belt bracket to the body bracket. Tighten the screws to 20 N.m (15 ft. lbs.). 5. Lift the webbing of the rear center seat belt and slide the cover (3) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Insert the rear center seat belt lower anchor between the rear seat back and the seat cushion, and position the anchor to the left side of the seat belt retractor mounting bracket on the rear floor panel. 10. Install and tighten the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. Tighten the screw to 40 N.m (29 ft. lbs.). 11. Tighten the screw that secures the right side of the seat belt retractor mounting bracket to the rear floor panel to 40 N.m (29 ft. lbs.). 12. Restore the rear seat cushion to its seating position. Rear Center - Mega Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6808 1. Fold the 60 percent section of the rear seat back (2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back filler panel (3) as necessary for easiest access to the rear center seat belt lower anchor and right outboard buckle anchor bracket. 2. Remove the screw (7) that secures the center seat belt lower anchor to the anchor bracket (3) and, from the front of the seat back, pull the belt lower anchor out from between the seat back (1) and the seat cushion (2). 3. Remove the two screws (3) that secure the bezel (2) to the top of the 60 percent section of the rear seat back (1). 4. Remove the bezel from the webbing of the rear center seat belt. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6809 5. Remove the trim cover from the 60 percent section of the rear seat back. 6. Remove the two screws (6) that secure the belt bracket (1) of the rear center seat belt to the top of the seat back frame (3). 7. Disengage the belt bracket of the rear center seat belt from the seat back frame. 8. Remove the screw (4) that secures the rear center seat belt retractor to the seat back frame. 9. Remove the seat belt and retractor from the rear seat back as a unit. INSTALLATION 1. Position the rear center seat belt and retractor unit into the 60 percent section of the rear seat back frame (3). Be certain the tab (5) on the retractor bracket is engaged in the slot in the frame. 2. Install and tighten the screw (4) that secures the rear center seat belt retractor to the seat back frame. Tighten the screw to 60 N.m (44 ft. lbs.). 3. Position the belt bracket (1) of the rear center seat belt onto the top of the seat back frame. Be certain the tab (2) on the bracket is engaged in the slot in the frame. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the seat back frame. Tighten the screws to 60 N.m (44 ft. lbs.). 5. Reinstall the trim cover onto the 60 percent section of the rear seat back frame. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6810 6. Engage the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the bezel over the belt bracket on the top of the rear seat back (1). 8. Install and tighten the two screws (3) that secure the bezel to the belt bracket on the top of the rear seat back frame. Tighten the screws to 5 N.m (44 in. lbs.). 9. Route the center seat belt lower anchor between the seat back (1) and the seat cushion (2) and position it to the anchor bracket (3). Be certain the belt webbing is not twisted between the retractor and the anchor bracket. 10. Install and tighten the screw (7) that secures the seat belt lower anchor to the anchor bracket. Tighten the screw to 40 N.m (30 ft. lbs.). 11. Restore the 60 percent seat back filler panel and the seat back to their previous positions. Rear Outboard - Quad Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6811 REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (5) that secures the seat belt lower anchor (6) to the base of the inner C-pillar. 3. Unsnap the trim cover (3) from the front seat belt turning loop (2) and discard. 4. Remove the screw (4) that secures the seat belt turning loop to the upper C-pillar. 5. Remove the seat belt turning loop from the upper C-pillar. 6. Remove the upper trim (1) from the inside of the C-pillar. 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6812 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (1) onto the inside of the C-pillar. 6. Position the seat belt turning loop (2) onto the upper C-pillar. 7. Install and tighten the screw (4) that secures the turning loop to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (6) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (5) that secures the lower anchor to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Rear Outboard - Mega Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6813 - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (6) that secures the seat belt lower anchor (7) to the base of the inner C-pillar. 3. Unsnap the trim cover (4) from the front seat belt turning loop (3) and discard. 4. Remove the screw (5) that secures the seat belt turning loop to the height adjuster (1) on the upper C-pillar. 5. Remove the seat belt turning loop from the height adjuster. 6. Remove the upper trim (2) from the inside of the C-pillar. 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Seat Belt > Page 6814 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (2) onto the inside of the C-pillar. 6. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper C-pillar. 7. Install and tighten the screw (5) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (4) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (7) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (6) that secures the lower anchor to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckle: Service and Repair Front WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. FRONT OUTBOARD REMOVAL NOTE: A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all models. The seat belt buckle on the driver's side front seat for all models also includes a seat belt switch. 1. Move the right or left front outboard seat section to its most rearward position and tilt the seat back forward for easiest access to the front outboard seat belt buckle lower anchor. 2. On standard cab models only, also move the outboard seat section opposite the side from which the buckle is to be removed to its most forward position and tilt the seat back forward. 3. On standard cab models only, remove the stowage tray from the rear floor panel behind the seat. 4. For buckles equipped with a seat belt switch, from behind the front seat disconnect the seat belt switch pigtail wire connector (4) from the seat wire harness take out and connector located on the lower inboard side of the seat cushion frame just forward of the buckle lower anchor. 5. From behind the front seat, remove the screw (3) that secures the buckle (1) lower anchor to the lower inboard side of the seat cushion frame. 6. From the front of the front seat, reach between the center seat cushion (2) or center floor console and the right or left front outboard seat cushion to access and remove the front outboard seat belt buckle from the seat. INSTALLATION NOTE: A traveling front outboard seat belt buckle is located on the inboard side of each front outboard seat section (40 percent) used on all models. The seat belt buckle on the driver's side front seat for all models also includes a seat belt switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 6819 1. From the front of the front seat, reach between the center seat cushion (2) or center floor console and the right or left front outboard seat cushion to position the front outboard seat belt buckle to the seat. 2. From behind the front seat, position the front outboard seat belt buckle lower anchor to the lower inboard side of the seat cushion frame. Be certain to engage the anti-rotation tab on the lower anchor into the corresponding hole in the seat cushion frame. 3. Install and tighten the screw (3) that secures the front outboard seat belt buckle lower anchor to the seat cushion frame. Tighten the screw to 25 N.m (18 ft. lbs.). 4. For buckles equipped with a seat belt switch, reconnect the seat belt switch pigtail wire connector (4) to the seat wire harness take out and connector located on the lower inboard side of the seat cushion frame just forward of the buckle lower anchor. 5. On standard cab models only, reinstall the stowage tray onto the rear floor panel behind the seat. FRONT CENTER & CENTER ANCHOR REMOVAL NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab models have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab models. 1. Move the adjacent right or left front outboard seat section (40 percent) to its most forward position and tilt the seat back forward for easiest access to the lower anchor of the front center seat belt buckle, lap belt or anchor buckle (1). 2. On standard cab models only, remove the stowage tray from the rear floor panel behind the seat. 3. From behind the front seat, remove the screw (5) that secures the lower anchor of the front center seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). 4. From the front of the front seat, reach between the side of the center seat cushion (6) and the adjacent right or left front outboard seat cushion to access and remove the seat belt buckle, lap belt or anchor buckle through the elastic strap (2) on the side of the center seat cushion. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 6820 5. Remove the front center seat belt buckle, lap belt or anchor buckle unit from the front seat. INSTALLATION NOTE: A fixed position front center seat belt buckle is located on the left side of the front center seat section (20 percent) used on all models. Standard cab models have a unique, fixed position, black, keyed, lower anchor buckle for the three-point center seat belt lower anchor located on the right side of the front center seat section. Quad cab and mega cab models have a fixed position front center seat lap belt located on the right side of the front center seat section. The following procedure applies to the front center seating position belt buckle, the lap belt or the anchor buckle. The three-point front center seat belt and retractor unit is only used on standard cab models. 1. From the front of the front seat, position the front center seat belt buckle, lap belt or anchor buckle unit (1) through the elastic strap (2) on the side of the center seat cushion (6). 2. From the front of the front seat, reach between the side of the center seat cushion and the adjacent right or left front outboard seat cushion to route the lower anchor of the seat belt buckle, lap belt or anchor buckle unit down between the side of the center seat cushion and the adjacent right or left front outboard seat cushion. Be certain that the belt webbing is not twisted. 3. From behind the front seat, position the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket (3). Be certain to engage the anti-rotation tab on the lower anchor into the corresponding hole in the center seat support bracket. 4. Install and tighten the screw (5) that secures the lower anchor of the seat belt buckle, lap belt or anchor buckle to the center seat support bracket. Tighten the screw to 40 N.m (29 ft. lbs.). 5. On standard cab models only, reinstall the stowage tray onto the rear floor panel behind the seat. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 6821 Seat Belt Buckle: Service and Repair Rear WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. REAR - QUAD CAB NOTE: The following removal procedure covers service of the rear seat center and left outboard seat belt buckle units. The rear seat right outboard seat belt buckle is serviced as a unit with the rear seat center seat belt and retractor assembly. REMOVAL 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (2) that secures either the center (4) or the left outboard (3) occupant buckle unit to the rear floor panel near the base of the cab back panel (1). On vehicles with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 3. Remove the center or left outboard occupant buckle unit from the rear floor panel or from the rear seat mounting bracket. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 6822 1. Position the center (4) or the left outboard (3) occupant buckle unit onto the rear floor panel or onto the rear seat mounting bracket near the base of the cab back panel (1). On vehicles with the optional 60/40 split rear bench, the screw that secures the buckle unit also secures one of the rear seat mounting brackets to the rear floor panel. 2. Install and tighten the screw (2) that secures the center or the left outboard occupant buckle unit to the rear floor panel. Tighten the screw to 40 N.m (29 ft. lbs.). 3. Restore the rear seat cushion to its seating position. REAR CENTER & LEFT OUTBOARD - MEGA CAB REMOVAL 1. Fold both the 40 percent section and the 60 percent section of the rear seat back (1 & 2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back filler panels (3 & 4) as necessary for easiest access to the rear center and left outboard seat belt buckle anchor bracket. 2. Remove the four screws (2) that secure the stabilizer bracket (4) to the two inboard seat hinge brackets. 3. Remove the stabilizer bracket from between the seat hinge brackets. 4. Remove and discard the screw (3) that secures the buckle anchor bracket (5) and the rear seat rear mounting bracket to the rear floor panel. 5. Remove the nut (1) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. 6. Disengage the buckles from between the seat cushion and the seat back, then remove the anchor bracket and buckles from between the rear seat sections as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 6823 1. Position the buckles and anchor bracket (5) between the inboard rear seat hinge brackets and engage the buckle units between the seat cushion and the seat back as a unit. Be certain to engage the anti-rotation tab on the anchor bracket into the clearance hole in the rear seat rear mounting bracket. 2. Install and tighten the nut (1) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. Tighten the nut to 23 N.m (17 ft. lbs.). 3. Install and tighten a new screw (3) to secure the buckle anchor bracket and the rear seat rear mounting bracket to the rear floor panel. Tighten the screw to 47 N.m (35 ft. lbs.). 4. Position the stabilizer bracket (4) between the two inboard rear seat hinge brackets. 5. Install and tighten the four screws (2) that secure the stabilizer bracket to the hinge brackets. Tighten the screws to 5 N.m (44 in. lbs.). 6. Restore both seat back filler panels and both seat backs to their previous positions. REAR CENTER ANCHOR & RIGHT OUTBOARD - MEGA CAB NOTE: The rear seat right outboard occupant buckle is serviced as a unit with an anchor bracket. The lower anchor of the rear center seat belt and retractor is also secured to the anchor bracket with a screw so that it can be removed from the anchor bracket and serviced separately from the buckle. REMOVAL 1. Fold the 60 percent section of the rear seat back (2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back filler panel (3) as necessary for easiest access to the rear center seat belt lower anchor and right outboard buckle anchor bracket. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front > Page 6824 2. Remove the screw (7) that secures the center seat belt lower anchor to the anchor bracket (3) and temporarily secure the belt lower anchor to keep it from being pulled from between the seat back (1) and the seat cushion (2) by the retractor. 3. Remove and discard the screw (6) that secures the buckle anchor bracket and the rear seat rear mounting bracket (5) to the rear floor panel. 4. Remove the nut (4) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. 5. Disengage the buckle from between the seat cushion and the seat back, then remove the anchor bracket and buckle from behind the rear seat as a unit. INSTALLATION 1. Engage the buckle unit between the seat cushion (2) and the seat back (1), then position the anchor bracket (3) to the rear seat rear mounting bracket (5) behind the rear seat as a unit. Be certain to engage the anti-rotation tab on the anchor bracket into the clearance hole in the mounting bracket. 2. Install and tighten the nut (4) that secures the buckle anchor bracket to the stud on the rear seat rear mounting bracket. Tighten the nut to 23 N.m (17 ft. lbs.). 3. Install and tighten a new screw (6) to secure the buckle anchor bracket and the rear seat rear mounting bracket to the rear floor panel. Tighten the screw to 47 N.m (35 ft. lbs.). 4. Route the center seat belt lower anchor between the seat back and the seat cushion and position it to the anchor bracket. Be certain the belt webbing is not twisted between the retractor and the anchor bracket. 5. Install and tighten the screw (7) that secures the seat belt lower anchor to the anchor bracket. Tighten the screw to 40 N.m (30 ft. lbs.). 6. Restore the 60 percent seat back filler panel and the seat back to their previous positions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6828 Seat Belt Buckle Switch: Description and Operation All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electromechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The driver side seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair Seat Belt Height Adjuster: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. REMOVAL FRONT 1. Unsnap the trim cover from the front seat belt turning loop and discard. 2. Remove the screw that secures the seat belt turning loop to the height adjuster (2) on the inside of the upper B-pillar (1). 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim from the inside of the B-pillar. 5. Loosen the two screws (3) that secure the height adjuster far enough to remove the adjuster from the upper B-pillar. 6. Disengage the tab near the lower end of the height adjuster from the slot in the sheet metal and remove the adjuster from the inside of the B-pillar. INSTALLATION 1. Position the front seat belt turning loop height adjuster (2) to the inside of the B-pillar (1). 2. Engage the tab near the lower end of the height adjuster into the slot in the sheet metal of the inner B-pillar. 3. Hand tighten the lower of the two screws (3) that secure the height adjuster to the B-pillar far enough to keep the tab on the lower end of the adjuster engaged in the B-pillar slot. 4. Install the upper screw that secures the seat belt turning loop height adjuster to the upper B-pillar, then tighten both the upper and lower screws to 39 N.m (29 ft. lbs.). 5. Reinstall the upper trim onto the inside of the B-pillar. 6. Position the seat belt turning loop onto the height adjuster on the upper B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6832 7. Install and tighten the screw that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 8. Engage the upper edge of a new trim cover over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. REAR - MEGA CAB REMOVAL 1. Unsnap the trim cover (4) from the front seat belt turning loop (3) and discard. 2. Remove the screw (5) that secures the seat belt turning loop to the height adjuster (1) on the upper C-pillar. 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim (2) from the inside of the C-pillar. 5. Loosen the two screws that secure the height adjuster far enough to remove the adjuster from the upper C-pillar. 6. Disengage the tab of the height adjuster from the slot in the sheet metal and remove the adjuster from the inside of the C-pillar. INSTALLATION 1. Position the rear seat belt turning loop height adjuster (1) to the inside of the upper C-pillar. 2. Engage the tab on the height adjuster into the slot in the sheet metal of the inner C-pillar. 3. Hand tighten the lower of the two screws that secure the height adjuster to the C-pillar far enough to keep the tab on the adjuster engaged in the C-pillar slot. 4. Install the upper screw that secures the seat belt turning loop height adjuster to the upper C-pillar, then tighten both the upper and lower screws to 39 N.m (29 ft. lbs.). 5. Reinstall the upper trim (2) onto the inside of the C-pillar. 6. Position the seat belt turning loop (3) onto the height adjuster on the upper C-pillar. 7. Install and tighten the screw (5) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (4) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Page 6833 together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or beltminder feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the Off position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about sixty seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 8 kilometers-per-hour (5 miles-per-hour), the seatbelt indicator will begin to cycle between flashing on and off for three seconds, then lighting solid for two seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for thirteen complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Occupant Restraint Controller (ORC), then flash the seatbelt indicator on and off. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The seatbelt switch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, refer to testing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming Seat Belt Reminder Lamp: Service and Repair Enhanced Seatbelt Reminder Programming The seatbelt indicator also includes a programmable enhanced seatbelt reminder or beltminder feature that is enabled when the vehicle is shipped from the factory. This beltminder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The beltminder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming > Page 6839 Seat Belt Reminder Lamp: Service and Repair Customer Programming Sequence NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. 1. With all doors closed and the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except On or Start to toggle the beltminder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation Seat Belt Retractor: Description and Operation The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism (7) as standard equipment. However, the retractor locking mechanisms for all seating positions except the driver's side front position are mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in any seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the seat belt and retractor unit and is concealed beneath a molded plastic cover located on one side of the retractor spool. The automatic locking mechanism cannot be adjusted or repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The locked mode of the automatic locking retractor is engaged and the retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make a light, audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the light, audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front Front Center - Standard Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Reach between the center of the front seat cushion and front seat back to access and unbuckle the front center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle. Use an ignition key or a small screwdriver to depress the small white release button on the anchor buckle. 2. Move the front seat to its most forward position for easiest access to the front center seat belt and retractor unit. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Using a trim stick or another suitable wide flatbladed tool, gently pry at each side of the front center seat belt bezel (5) on the cab back trim panel (1) to release the snap features that secure the bezel to the panel. 5. Remove the bezel from the webbing of the front center seat belt (4). 6. Remove the trim from the cab back panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6845 7. Remove the two screws (3) that secure the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel (8) reinforcement. 8. Remove the belt bracket of the front center seat belt from the body bracket on the upper cab back panel reinforcement. 9. Remove the two screws (4) that secure the front center seat belt retractor bracket (5) to the floor panel (6) near the base of the cab back panel. 10. Remove the front center seat belt and retractor unit from the floor panel. INSTALLATION 1. Position the front center seat belt and retractor unit (5) to the floor panel (6) at the base of the cab back panel (8) to the right of center. 2. Install and tighten the two screws (4) that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel. Tighten the screws to 40 N.m (29 ft. lbs.). 3. Position the belt bracket (2) of the front center seat belt (7) to the body bracket (1) on the upper cab back panel reinforcement. 4. Install and tighten the two screws (3) that secure the belt bracket of the front center seat belt to the body bracket on the upper cab back panel reinforcement. Tighten the screws to 20 N.m (15 ft. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6846 5. Reinstall the trim (1) onto the cab back panel. 6. Route the webbing of the front center seat belt (4) through the bezel (5) and position the bezel to the belt opening near the top of the cab back trim panel. 7. Using hand pressure, press firmly and evenly on each side of the front center seat belt bezel until it snaps into place on the cab back trim panel. 8. Reinstall the stowage tray onto the rear floor panel behind the seat. 9. Reach between the center of the front seat cushion and front seat back to access and buckle the front center seat belt lower anchor latch plate to the unique black, keyed lower anchor buckle. Front Outboard - Quad and Mega Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - The following procedure is for replacement of a faulty or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6847 1. Adjust the front seat to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 4. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 5. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 6. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper trim (2) from the inside of the B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6848 9. Remove the lower trim (3) from the inside of the B-pillar. 10. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 11. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 12. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 13. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 14. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 15. Remove the front outboard seat belt and retractor from the B-pillar as a unit. INSTALLATION 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 N.m (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6849 8. Reinstall the upper trim (2) onto the inside of the B-pillar. 9. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 10. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 11. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 12. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 13. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 N.m (29 ft. lbs.). 14. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 15. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Front Outboard - Standard Cab WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6850 LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - The following procedure is for replacement of a faulty or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is faulty or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. - The seat belt retractor on the driver's side of all standard cab models includes a tension reducer. All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Adjust the front seat (1) to its most forward position for easiest access to the front seat belt (2) lower anchor cover (4) and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the stowage tray from the rear floor panel behind the seat. 4. Grasp the upper edge of the lower anchor cover and pull upward to unsnap it from the front seat cushion outboard side shield. 5. Remove the screw (3) that secures the lower anchor to the outboard side of the front seat cushion frame. 6. Unsnap the trim cover (3) from the front seat belt turning loop (5) and discard. 7. Remove the screw (4) that secures the seat belt turning loop to the height adjuster (1) on the upper B-pillar. 8. Remove the seat belt turning loop from the height adjuster. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6851 9. Remove the upper trim (2) from the inside of the B-pillar. 10. Remove the lower trim (3) from the inside of the B-pillar. 11. Disconnect the yellow body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 12. On the driver side only, disconnect the white body wire harness connector from the connector receptacle for the seat belt tension reducer located near the bottom of the retractor. 13. Disengage the two clips that secure the belt web guide (1) to the B-pillar. 14. Remove the screw (4) that secures the upper retractor bracket to the B-pillar. 15. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 16. Disengage the locating tab on the upper retractor bracket from the hole in the inner B-pillar. 17. Remove the front outboard seat belt and retractor from the B-pillar as a unit. INSTALLATION 1. Position the front outboard seat belt and retractor (7) to the inner B-pillar as a unit. Be certain to engage the tab on the upper retractor bracket into the hole in the B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (4) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 12 N.m (105 in. lbs.). 4. Tighten the screw that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 5. Position the belt web guide (1) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 6. Reconnect the yellow body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 7. On the driver side only, reconnect the white body wire harness connector to the seat belt tension reducer connector receptacle near the bottom of the retractor. 8. Reinstall the lower trim (3) onto the inside of the B-pillar. Be certain that the turning loop (2) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6852 9. Reinstall the upper trim (2) onto the inside of the B-pillar. 10. Position the seat belt turning loop (5) onto the height adjuster (1) on the upper B-pillar. 11. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 12. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 13. Position the seat belt (2) lower anchor to the mounting hole on the outboard side of the front seat (1) cushion frame. Be certain that the seat belt webbing between the turning loop and the lower anchor is not twisted. 14. Install and tighten the screw (3) that secures the lower anchor to the seat. Tighten the screw to 39 N.m (29 ft. lbs.). 15. Reinstall the lower anchor cover (4) onto the front seat cushion outboard side shield. 16. Reinstall the stowage tray onto the rear floor panel behind the seat. 17. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6853 Seat Belt Retractor: Service and Repair Rear Rear Center - Mega Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Fold the 60 percent section of the rear seat back (2) down onto the seat cushion in the cargo storage position, then lift and prop open the seat back filler panel (3) as necessary for easiest access to the rear center seat belt lower anchor and right outboard buckle anchor bracket. 2. Remove the screw (7) that secures the center seat belt lower anchor to the anchor bracket (3) and, from the front of the seat back, pull the belt lower anchor out from between the seat back (1) and the seat cushion (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6854 3. Remove the two screws (3) that secure the bezel (2) to the top of the 60 percent section of the rear seat back (1). 4. Remove the bezel from the webbing of the rear center seat belt. 5. Remove the trim cover from the 60 percent section of the rear seat back. 6. Remove the two screws (6) that secure the belt bracket (1) of the rear center seat belt to the top of the seat back frame (3). 7. Disengage the belt bracket of the rear center seat belt from the seat back frame. 8. Remove the screw (4) that secures the rear center seat belt retractor to the seat back frame. 9. Remove the seat belt and retractor from the rear seat back as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6855 1. Position the rear center seat belt and retractor unit into the 60 percent section of the rear seat back frame (3). Be certain the tab (5) on the retractor bracket is engaged in the slot in the frame. 2. Install and tighten the screw (4) that secures the rear center seat belt retractor to the seat back frame. Tighten the screw to 60 N.m (44 ft. lbs.). 3. Position the belt bracket (1) of the rear center seat belt onto the top of the seat back frame. Be certain the tab (2) on the bracket is engaged in the slot in the frame. 4. Install and tighten the two screws (6) that secure the belt bracket of the rear center seat belt to the seat back frame. Tighten the screws to 60 N.m (44 ft. lbs.). 5. Reinstall the trim cover onto the 60 percent section of the rear seat back frame. 6. Engage the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the bezel over the belt bracket on the top of the rear seat back (1). 8. Install and tighten the two screws (3) that secure the bezel to the belt bracket on the top of the rear seat back frame. Tighten the screws to 5 N.m (44 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6856 9. Route the center seat belt lower anchor between the seat back (1) and the seat cushion (2) and position it to the anchor bracket (3). Be certain the belt webbing is not twisted between the retractor and the anchor bracket. 10. Install and tighten the screw (7) that secures the seat belt lower anchor to the anchor bracket. Tighten the screw to 40 N.m (30 ft. lbs.). 11. Restore the 60 percent seat back filler panel and the seat back to their previous positions. Rear Center - Quad Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The rear center seat belt and retractor is secured to a mounting bracket that includes the right outboard occupant seat belt buckle. The rear right outboard occupant buckle is available for service only as a unit with the center seat belt and retractor. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6857 1. Lift up the rear seat cushion into its stowed position against the rear seat back. 2. Remove the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. 3. Remove the rear seat from the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be removed. 4. Lift upward on the forward edge of the rear center seat belt bezel (2) at the top of the cab back panel (1) to release the snap features that secure the bezel to the belt bracket. 5. Remove the bezel from the webbing of the rear center seat belt. 6. Lift the rear center seat belt cover (3) off of the belt bracket at the top of the cab back panel and remove the cover from the webbing of the rear center seat belt. 7. Remove the two screws (4) that secure the belt bracket of the rear center seat belt to the body bracket on the upper cab back panel reinforcement. 8. Remove the belt bracket of the rear center seat belt from the body bracket. 9. Remove the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle (6) unit to the rear floor panel near the base of the cab back panel. 10. Remove the rear center seat belt and retractor unit from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6858 1. Position the rear center seat belt retractor and right outboard occupant buckle unit (6) onto the rear floor panel near the base of the cab back panel (1). 2. Loosely install the screw (7) that secures the right side of the seat belt retractor mounting bracket and the right outboard occupant buckle unit to the rear floor panel near the base of the cab back panel. 3. Position the belt bracket of the rear center seat belt onto the body bracket on the upper cab back panel reinforcement. 4. Install and tighten the two screws (4) that secure the belt bracket to the body bracket. Tighten the screws to 20 N.m (15 ft. lbs.). 5. Lift the webbing of the rear center seat belt and slide the cover (3) over the belt bracket at the top of the cab back panel until it is fully seated. 6. Route the rear center seat belt bezel (2) over the webbing of the rear center seat belt. 7. Position the rear center seat belt bezel over the cover and belt bracket at the top of the cab back panel and engage the rearward snap features of the bezel with the belt bracket. Using hand pressure, press firmly and evenly downward on the front of the bezel until it snaps into place over the cover and belt bracket. 8. Reinstall the rear seat into the vehicle. On vehicles with the optional 60/40 split rear bench, only the 60 percent section (right side) of the rear seat must be reinstalled. 9. Insert the rear center seat belt lower anchor between the rear seat back and the seat cushion, and position the anchor to the left side of the seat belt retractor mounting bracket on the rear floor panel. 10. Install and tighten the screw (5) that secures the center seat belt lower anchor and the left side of the seat belt retractor mounting bracket to the rear floor panel. Tighten the screw to 40 N.m (29 ft. lbs.). 11. Tighten the screw that secures the right side of the seat belt retractor mounting bracket to the rear floor panel to 40 N.m (29 ft. lbs.). 12. Restore the rear seat cushion to its seating position. Rear Outboard - Mega Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6859 1. Remove the rear seat from the vehicle. 2. Remove the screw (6) that secures the seat belt lower anchor (7) to the base of the inner C-pillar. 3. Unsnap the trim cover (4) from the front seat belt turning loop (3) and discard. 4. Remove the screw (5) that secures the seat belt turning loop to the height adjuster (1) on the upper C-pillar. 5. Remove the seat belt turning loop from the height adjuster. 6. Remove the upper trim (2) from the inside of the C-pillar. 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6860 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (2) onto the inside of the C-pillar. 6. Position the seat belt turning loop (3) onto the height adjuster (1) on the upper C-pillar. 7. Install and tighten the screw (5) that secures the turning loop to the height adjuster. Tighten the screw to 39 N.m (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (4) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (7) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (6) that secures the lower anchor to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Rear Outboard - Quad Cab WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR. REPLACE ANY BELT THAT HAS A BENT OR DAMAGED LATCH PLATE OR ANCHOR PLATE. REPLACE ANY CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT OR CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. NOTE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6861 - The only component of this seat belt and retractor unit that is available for individual service replacement is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position. Refer to the instructions supplied with the service kit for the proper web stop button replacement procedures. - All seat belt retractors except the driver's side front retractor include a switchable automatic locking mechanism. REMOVAL 1. Remove the rear seat from the vehicle. 2. Remove the screw (5) that secures the seat belt lower anchor (6) to the base of the inner C-pillar. 3. Unsnap the trim cover (3) from the front seat belt turning loop (2) and discard. 4. Remove the screw (4) that secures the seat belt turning loop to the upper C-pillar. 5. Remove the seat belt turning loop from the upper C-pillar. 6. Remove the upper trim (1) from the inside of the C-pillar. 7. Remove the lower trim (2) from the inside of the C-pillar. 8. Disengage the two clips that secure the belt web guide (5) to the C-pillar. 9. Remove the screw (3) that secures the lower bracket of the retractor (4) to the C-pillar. 10. Disengage the hooks on the upper retractor bracket from the slots in the C-pillar above the retractor mounting hole. 11. Remove the rear outboard seat belt and retractor from the C-pillar as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 6862 1. Position the rear outboard seat belt and retractor (4) to the inner C-pillar as a unit. Be certain to engage the hooks on the upper retractor bracket into the mounting hole in the C-pillar. 2. Install and tighten the screw (3) that secures the lower retractor bracket to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 3. Position the belt web guide (5) to the B-pillar and use hand pressure to press it firmly and evenly until the two clips that secure it snap into place. 4. Reinstall the lower trim (2) onto the inside of the C-pillar. Be certain that the turning loop (1) can be accessed from the face of the lower trim after the seat belt webbing is inserted through the slot in the trim. 5. Reinstall the upper trim (1) onto the inside of the C-pillar. 6. Position the seat belt turning loop (2) onto the upper C-pillar. 7. Install and tighten the screw (4) that secures the turning loop to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 8. Engage the upper edge of a new trim cover (3) over the top of the turning loop. Then squeeze the lower end of the trim cover and the turning loop together firmly and evenly until the engagement tabs of the trim cover snap into the slots of the turning loop. 9. Position the seat belt lower anchor (6) to the mounting hole at the base of the C-pillar. 10. Install and tighten the screw (5) that secures the lower anchor to the C-pillar. Tighten the screw to 39 N.m (29 ft. lbs.). 11. Reinstall the rear seat into the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams Seat Belt Tensioner: Diagrams Seat Belt-Tension Reducer - Driver (Standard Cab) Seat Belt-Tensioner - Driver Seat Belt-Tensioner - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt-Tensioner Seat Belt Tensioner: Description and Operation Seat Belt-Tensioner Seat belt tensioners supplement the dual front airbags for this model. The seat belt tensioners are integral to the front outboard seat belt retractor units, which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube, a cast metal housing, numerous steel balls, a stamped metal ball trap, a torsion bar and a small pyrotechnically activated gas generator with a connector receptacle. All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching yellow molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if faulty or damaged, the entire front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of harmful contact with the steering wheel, steering column, instrument panel and/or windshield. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the Electromechanical Instrument Cluster (EMIC) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. For proper diagnosis of the seat belt tensioners, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt-Tensioner > Page 6868 Seat Belt Tensioner: Description and Operation Seat Belt Tension Reducer A seat belt tension reducer is standard equipment for the driver side front outboard seat belt on standard cab versions of this model. The tension reducer is integral to the retractor unit, which is secured to the inner B-pillar on the left side of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tension reducer consists primarily of a 12-volt Direct Current (DC) solenoid and an integral connector receptacle that is located on the forward facing end housing of the retractor. The seat belt tension reducer is controlled by a battery current output of the ignition switch and a ground path provided by the seat belt switch, and is connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching molded plastic connector insulator to ensure a secure connection. The seat belt tension reducer cannot be repaired and, if faulty or damaged, the entire driver side front outboard seat belt and retractor unit must be replaced. The seat belt tension reducer is controlled by a ground signal received from the seat belt switch on the seat belt switch sense circuit and a battery current signal received from the ignition switch on the fused ignition switch output (run-accessory) circuit. When the seat belt switch is closed (the driver side front seat belt is fastened) and the ignition switch is in the On or Accessory positions, the seat belt tension reducer solenoid is energized. When the solenoid is energized, it actuates a mechanism within the driver side front outboard seat belt retractor to reduce the normal recoil spring tension exerted by the retractor spool, which is designed to reel in the seat belt webbing onto the spool. When the driver side seat belt is unbuckled or if the ignition switch is turned to any position except On or Accessory, the tension reducer solenoid is de-energized and the normal recoil spring tension of the retractor is restored. The action of the seat belt tension reducer results in improved seat belt comfort for the driver. Reducing the seat belt retractor recoil spring tension is desirable on standard cab models of this vehicle and not on the quad cab or mega cab models due to the different mounting position required for the seat belt turning loop on the B-pillar relative to the driver's seat position on the standard cab model. The seat belt tension reducer may be diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Page 6869 Seat Belt Tensioner: Testing and Inspection SEAT BELT TENSION REDUCER Refer to Diagram/Electrical. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the seat belt tension reducer from the tension reducer connector receptacle on the driver side front outboard seat belt and retractor unit. Using an ohmmeter, measure the resistance between the seat belt switch sense circuit terminal pin and the fused ignition switch output (run-accessory) circuit terminal pin in the tension reducer connector receptacle on the retractor. Resistance through the tension reducer solenoid coil should be 53 ohms at 20° C (68° F). If OK, go to Step 2. If not OK, replace the faulty driver side front outboard seat belt and retractor unit. 2. Check for continuity between the seat belt switch sense circuit cavity of the body wire harness connector for the seat belt tension reducer and a good ground. There should be continuity with the driver side front seat belt buckled, and no continuity with the driver side front seat belt unbuckled. If OK, go to Step 3. If not OK, repair the shorted or open seat belt switch sense circuit between the tension reducer and the seat belt switch as required. 3. Reconnect the battery negative cable. Check for battery current at the fused ignition switch output (run-accessory) circuit of the body wire harness connector for the seat belt tension reducer. There should be battery current with the ignition switch in the On or Accessory positions, and no battery current with the ignition switch in any other position. If not OK, repair the shorted or open fused ignition switch output (run-accessory) circuit between the tension reducer and the ignition switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams Sensor-Seat Track Position - Driver Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 6873 Seat Sensor/Switch: Description and Operation The seat track position sensor (2) is a Hall Effect-type sensor used on some models. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if faulty or damaged, the entire sensor must be replaced. The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the CAN data bus to illuminate the airbag indicator in the instrument cluster. For proper diagnosis of the seat track position sensor, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 6874 Seat Sensor/Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. INSTALLATION 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations Air Bag Deactivation Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6879 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6880 Switch - Passenger Airbag On/Off Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6881 Air Bag Deactivation Switch: Description and Operation The passenger airbag on/off switch (1) is standard equipment on all standard cab versions of this model equipped with the dual front airbag system. This switch is a two-position, resistor multiplexed switch with a single integral amber Light-Emitting Diode (LED), and a non-coded key cylinder-type actuator. The switch is located in the lower right corner of the instrument panel center bezel, near the center of the instrument panel. When the switch is in its installed position, the only components visible through the dedicated opening of the center bezel are the switch bezel (2) and lens, the nomenclature imprinted on the lens, and the key cylinder actuator (3). The "Off" position nomenclature of the switch is illuminated and visible only when that switch position is selected. The "On" position of the switch is neither visible or illuminated but can be determined by the orientation of the slot of the key cylinder actuator. The remainder of the switch is concealed behind the switch bezel and the instrument panel center bezel. The passenger airbag on/off switch housing is constructed of molded plastic and has three integral mounting tabs. These mounting tabs are used to secure the switch to the back of the molded plastic switch bezel with three small screws. The molded plastic switch bezel also has three integral mounting tabs that are used to secure the switch and bezel unit to the instrument panel center bezel with three additional screws. A molded plastic connector receptacle on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to ensure proper and secure switch electrical connections. The passenger airbag on/off switch cannot be adjusted or repaired and, if faulty or damaged, the switch must be replaced. The passenger airbag on/off switch allows the customer to turn the passenger airbag function On or Off to accommodate certain uses of the right front seating position where airbag protection may not be desired. See the vehicle glove box for specific recommendations on when to enable or disable the passenger airbag. The Off indicator of the switch will be illuminated whenever the switch is turned to the Off position and the ignition switch is in the On position. The ignition key is the only key or object that should ever be inserted into the key cylinder actuator of the switch. The on/off switch requires only a partial key insertion to fully depress a spring-loaded locking plunger. The spring loaded locking plunger prevents the user from leaving the key in the switch. The key will be automatically ejected when force is not applied. To actuate the passenger airbag on/off switch, insert the ignition key into the switch key actuator far enough to fully depress the plunger, then rotate the actuator to the desired switch position. When the switch key actuator is rotated to its clockwise stop (the key actuator slot will be aligned with the Off nomenclature), the Off indicator is illuminated and the passenger airbag is disabled. When the switch is rotated to its counterclockwise stop (the key actuator slot will be in a vertical position) the Off indicator will be extinguished and the passenger airbag is enabled. The Off indicator and the enabling or disabling of the passenger airbag is controlled electronically by the Occupant Restraint Controller (ORC) based upon inputs it receives from the on/off switch. The passenger airbag on/off switch connects one of two internal resistors in series between the passenger airbag mux switch sense and passenger airbag mux switch return circuits of the ORC. The ORC continually monitors the resistance in these circuits to determine the switch position that has been selected. When the switch is in the Off position, the ORC provides a ground input to the Off indicator through the passenger airbag indicator driver circuit, which energizes the Light-Emitting Diode (LED) that illuminates the indicator. The ORC will store a Diagnostic Trouble Code (DTC) for any fault it detects in the passenger airbag on/off switch or Off indicator circuits, and will illuminate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the passenger airbag on/off switch or the ORC, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6882 Air Bag Deactivation Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: A passenger airbag on/off switch is used only on standard cab models equipped with dual front airbags. Quad cab and mega cab models have a cubby bin installed in the instrument panel center bezel in place of the on/off switch. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the center bezel (1) from the instrument panel. 3. From the back of the center bezel, remove the three screws (2) that secure the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel. 4. Remove the passenger airbag on/off switch and bezel from the center bezel as a unit. INSTALLATION 1. Position the passenger airbag on/off switch and bezel unit (3) to the back of the center bezel (1). 2. Install and tighten the three screws (2) that secure the passenger airbag on/off switch bezel to the back of the center bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Reinstall the center bezel onto the instrument panel. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Locations > Page 6883 following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6887 Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6888 Left Side Body - Standard Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6889 Standard Cab Right Side Body Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6890 Left Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6891 Right Side Body - Quad Cab/Mega Cab Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6892 Impact Sensor: Diagrams Sensor-Front Impact - Left Sensor-Front Impact - Right Sensor-Side Impact - Left 1 Sensor-Side Impact - Right 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6893 Impact Sensor: Description and Operation FRONT Two front impact sensors (1) are used on this model, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front impact sensor is secured with a screw to the back of the right or left end of the lower radiator crossmember within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires the use of a diagnostic scan tool. Refer to Trouble Code Diagnostic Charts. SIDE Two side impact sensors (1) are used on this model when it is equipped with the optional side curtain airbags, one each for the left and right sides of the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 6894 vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Occupant Restraint Controller (ORC). Each side impact sensor is secured with a nut within the right or left B-pillar just above the front seat belt retractors and behind the lower B-pillar trim within the passenger compartment. The sensor housing has an integral connector receptacle (2), an integral mounting stud (3), and an integral anti-rotation pin. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The side impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC, the impact sensors, or the electronic message inputs to or outputs from the impact sensors. The most reliable, efficient, and accurate means to diagnose the impact sensors, the ORC, and the electronic message communication between the sensors and the ORC requires the use of a diagnostic scan tool. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor: Service and Repair Front WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE FRONT IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE FRONT IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE FRONT SUPPLEMENTAL RESTRAINTS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER FRONT SUPPLEMENTAL RESTRAINT DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Remove the screw (4) that secures the right or left front impact sensor (3) to the back of the right or left end of the lower radiator crossmember (1). 3. Disconnect the headlamp and dash wire harness connector (2) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. INSTALLATION 1. Position the right or left front impact sensor (3) into the engine compartment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6897 2. Reconnect the headlamp and dash wire harness connector (2) to the sensor connector receptacle. 3. Carefully position the sensor onto the back of the right or left end of the lower radiator crossmember (1). Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the crossmember. 4. Install and tighten the screw (4) that secures the sensor to the back of the crossmember. Tighten the screw to 10 N.m (90 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6898 Impact Sensor: Service and Repair Side WARNING: - TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. - TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS. IF AN IMPACT SENSOR IS ACCIDENTALLY DROPPED DURING SERVICE, THE SENSOR MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER SUPPLEMENTAL RESTRAINT DEPLOYMENT. SIDE - STANDARD CAB REMOVAL 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the front outboard seat belt and retractor from the inside of the B-pillar. 4. Remove the nut (4) that secures the stud of the side impact sensor (1) to the inner B-pillar. 5. Reach through the retractor mounting hole (3) in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 6. Pull the side impact sensor out of the B-pillar far enough to access and disconnect the body wire harness connector (2) from the sensor connector receptacle. 7. Remove the sensor from the B-pillar. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6899 1. Position the side impact sensor (1) to the retractor mounting hole (3) in the inner B-pillar. 2. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 3. Reach through the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (4) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Reinstall the front outboard seat belt and retractor to the inside of the B-pillar. 6. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. SIDE - QUAD CAB REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (2) to the inner B-pillar (1). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (4) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6900 INSTALLATION 1. Position the side impact sensor (2) to the large hole above the retractor mounting hole in the inner B-pillar (1). 2. Reconnect the body wire harness connector (4) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. SIDE - MEGA CAB REMOVAL 1. Adjust the front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 3. Remove the nut (3) that secures the stud of the side impact sensor (4) to the inner B-pillar (2). 4. Reach through the large hole above the retractor mounting hole in the inner B-pillar to access the side impact sensor and disengage the anti-rotation pin and mounting stud from the holes in the inner B-pillar. 5. Pull the side impact sensor out through the large hole in the B-pillar far enough to access and disconnect the body wire harness connector (1) from the sensor connector receptacle. 6. Remove the side impact sensor from the B-pillar. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front > Page 6901 1. Position the side impact sensor (4) to the large hole above the retractor mounting hole in the inner B-pillar (2). 2. Reconnect the body wire harness connector (1) to the sensor connector receptacle. 3. Reach through the large hole above the retractor mounting hole in the inner B-pillar to position and engage the anti-rotation pin and the stud on the side impact sensor to the locating slot and mounting hole from the inside of the B-pillar. 4. Install and tighten the nut (3) that secures the side impact sensor stud to the inner B-pillar. Tighten the nut to 8 N.m (70 in. lbs.). 5. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 6905 Seat Belt Buckle Switch: Description and Operation All vehicles are equipped with a driver side seat belt switch that is a small, normally open, single pole, single throw, leaf contact, momentary switch. The driver side seat belt switch is integral to the buckle (1) of the driver side front seat belt buckle, which is located on a stamped steel stanchion secured by a screw (3) to the inboard side of the driver side front seat cushion frame. The seat belt switch is connected to the vehicle electrical system through a two-lead pigtail wire and connector (4) on the seat belt buckle-half, which is connected to a wire harness connector and take out of the seat wire harness routed beneath the driver side front seat cushion in the passenger compartment. The seat belt switch cannot be adjusted or repaired. If faulty or damaged, the entire driver side front seat belt buckle-half unit must be replaced. The driver side seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electromechanical Instrument Cluster (EMIC). When the driver side front seat belt tip-half is inserted into the seat belt buckle, the switch closes the path to ground; and, when the driver side front seat belt tip-half is removed from the seat belt buckle, the switch opens the ground path. The switch is actuated by the latch mechanism within the seat belt buckle. The driver side seat belt switch is connected in series between ground and the seat belt switch sense input of the instrument cluster. The seat belt switch receives ground at all times through its pigtail wire connection to the seat wire harness from a take out of the body wire harness. An eyelet terminal connector on the body wire harness ground take out is secured beneath a ground screw on the left cowl side inner panel, beneath the instrument panel. The seat belt switch may de diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams Sensor-Seat Track Position - Driver Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 6909 Seat Sensor/Switch: Description and Operation The seat track position sensor (2) is a Hall Effect-type sensor used on some models. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has a mounting slot containing an integral latch feature (1) and slides and latches onto a stamped metal blade-type bracket located on the inboard side of the upper inboard seat adjuster track near the rear of the driver side front seat. A molded connector receptacle (3) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the driver seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if faulty or damaged, the entire sensor must be replaced. The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected, and sends messages over the CAN data bus to illuminate the airbag indicator in the instrument cluster. For proper diagnosis of the seat track position sensor, a diagnostic scan tool is required. Refer to Trouble Code Diagnostic Charts. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 6910 Seat Sensor/Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (2) on a bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Using a small screwdriver, hold the latch feature (3) depressed while sliding the connector end of the sensor off of the bracket. 4. Disconnect the seat wire harness connector (5) from the sensor connector receptacle. 5. Remove the sensor from under the front seat. INSTALLATION 1. Reach under the driver side front seat cushion to reconnect the seat wire harness connector (5) to the seat track position sensor (2) connector receptacle. Be certain that the latch on the connector is fully engaged. 2. Align the open end of the sensor to the slide tab of the sensor bracket (1) located on the inboard side near the rear of the upper inboard driver seat track (4). 3. Push the sensor firmly onto the bracket until the latch feature (3) snaps into place with an audible click. 4. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Revised Antenna Mast Installation Antenna Mast: Technical Service Bulletins Audio System - Revised Antenna Mast Installation NUMBER: 08-058-05 GROUP: Electrical DATE: October 29, 2005 SUBJECT: Revised Radio Antenna Mast Installation Procedure MODELS: 2005 - 2006 (DR/DH/D1) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (ND) Dakota 2005 - 2006 (PL) Neon 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan DISCUSSION: The installation procedure for the radio antenna mast has been revised. Please use the following procedure when installing the antenna mast to the antenna base. CAUTION: Do not exceed the torque specification in the step below. Damage to the antenna mast and/or base may occur if the tightening torque is exceeded. 1. Install antenna mast to antenna base. Finger tighten the antenna mast until it is fully seated on antenna base; no gap between the mast and base. Using a torque wrench, tighten the antenna mast to 3.4 - 3.6 N.m (30 - 32 in.lbs.) (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel top cover. 3. Remove the radio. 4. Remove the antenna mounting fasteners. 5. Cut each end of the cable (1) and leave remaining portion in the instrument panel. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Page 6920 1. Position new antenna cable to wire harness. Secure into place. 2. Install antenna mounting fasteners. 3. Install radio. 4. Install instrument panel top cover. 5. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Diagrams Antenna Cable: Diagrams Antenna Cable - Satellite Radio No.1 Antenna Cable - Satellite Radio No.2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation Each ignition key (2) used in the Sentry Key Immobilizer System (SKIS) has a transponder chip included on the circuit board (4) beneath the cover (1) of the integral Remote Keyless Entry (RKE) transmitter (3). In addition to having to be cut to match the mechanical coding of the ignition lock cylinder and programmed for operation of the RKE system, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key REmote Entry Module (SKREEM) to be recognized by the SKIS as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If faulty or damaged, the entire key and RKE transmitter unit must be replaced. When the ignition switch is turned to the On position, the Sentry Key REmote Entry Module (SKREEM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKREEM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKREEM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKREEM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKREEM to the Powertrain Control Module (PCM)/Engine Control Module (ECM) over the Controller Area Network (CAN) data bus, and the PCM/ECM allows the engine to continue running. If the PCM/ECM receives an invalid key message, or receives no message from the SKREEM over the CAN data bus, the engine will be disabled after about two seconds of operation. The Electro- Mechanical Instrument Cluster (EMIC) will also respond to the invalid key message on the CAN data bus by flashing the security indicator on and off. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKREEM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKREEM, the SKREEM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKREEM. Once the Sentry Key learns the Secret Key code of the SKREEM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6936 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 6937 Module - Sentry Key Remote Entry Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, refer to Keyless Entry Transmitter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 6940 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS) and is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. The Sentry Key REmote Entry Module (SKREEM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC), the Powertrain Control Module (PCM)/Engine Control Module (ECM), the Gateway module (SRT10 vehicles with a hybrid bus only) and the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then listens for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends a valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 6941 SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator status messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator status message from the SKREEM tells the EMIC to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator status messages to the EMIC to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM detects an invalid key or if a key transponder- related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The SKREEM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Page 6942 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry Keyless Entry Module: Service and Repair Module-Remote Keyless Entry REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 6945 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 6946 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 6947 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 6948 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation A security indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is electronically disabled. This indicator is located in the lower right quadrant of the instrument cluster, between the speedometer and the coolant temperature gauge. The security indicator consists of a small round cutout in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or is armed. On models equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, hard wired inputs to the cluster from the various security system components, and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The security indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. Depending upon the programmed condition the indicator can be illuminated solid, flashed at a slow rate (0.5 Hertz, 12.5 percent duty cycle), or flashed at a fast rate (1 Hertz , 50 percent duty cycle). The instrument cluster will turn on the security indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the security indicator illuminates for about two seconds as a bulb test. The entire bulb test is a function of the SKREEM. - VTSS Indication - During the sixteen second VTSS arming function, the cluster will flash the security indicator on and off repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the cluster flashes the security indicator on and off continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. If the VTSS has alarmed and rearmed, the cluster will flash the security indicator at a steady, slow rate for about thirty seconds after the VTSS is disarmed. SKIS Lamp-On Message - Each time the cluster receives a SKIS lamp-on message from the SKREEM, the security indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated solid or continues to flash until the cluster receives a SKIS lamp-off message from the SKREEM, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no SKIS lamp-on or lamp-off messages from the SKREEM for ten consecutive message cycles, the security indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid SKIS lamp-on or lamp-off message is received from the SKREEM. - Actuator Test - Each time the instrument cluster is put through the actuator test, the security indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster circuitry controls the security indicator whenever the ignition switch is in the Off position and the VTSS is arming, armed, or alarming. Whenever the ignition switch is in the On or Start positions, the SKREEM performs a self-test to decide whether the SKIS is in good operating condition and whether a valid key is present in the ignition lock cylinder. The SKREEM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the security indicator or the instrument cluster circuitry that controls the indicator, refer to testing. If the instrument cluster flashes the security indicator upon ignition On, or turns on the security indicator solid after the bulb test, it indicates that a SKIS malfunction has occurred or that the SKIS is inoperative. For proper diagnosis of the VTSS, the SKIS, the SKREEM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the security indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect Cellular Phone: Customer Interest Cell Phone - Hands Free Module Will Not Connect NUMBER: 08-014-06 GROUP: Electrical DATE: March 16, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-049-05 DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED REPAIR PROCEDURES. SUBJECT: Flash: Connect Hands Free Module Fails To Respond Due To Module Lock Up OVERVIEW: This bulletin involves flash reprogramming the Hands Free Module (HFM) module. MODELS: 2006 (DR/DH/D1) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2006 (PT) PT Cruiser 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with UConnect Hands Free Communications (sales code RSP) that were built prior to October 02, 2005 (MDH 1002XX). SYMPTOM/CONDITION: The Hands Free Module (HFM) fails to operate causing the UConnect Hands Free Communications system to not respond when system activation is attempted by the customer. Further diagnosis may reveal that when the StarSCAN(R) scan tool is used to read Diagnostic Trouble Codes (DTC's) the tool indicates that the module is not responding. Other modules on the bus may display loss of communication with the HFM. If the Hands Free Communication system is unresponsive then the HFM may require electronic reset. DIAGNOSIS: Attempt to reset (power reset) the HFM as follows: 1. With the ignition switch in the "Off" position, remove the "Ignition Off Draw" (IOD) fuse and wait 10 seconds. 2. Install the IOD fuse. 3. Turn the ignition to the "On" position (engine not running). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6964 4. After the module is reset, press the "Phone Button" on the rear view mirror to activate the UConnect Hands Free system and to verify proper system operation (Fig. 1). Did the UConnect Hands Free system reset and now operates properly? a. Yes >> Perform Repair Procedure. b. No >> This bulletin does not apply. Further diagnosis is required. Continue diagnosis as needed using the existing diagnostic procedures available in TechCONNECT under: Service Info, 8 Electrical, Navigation/Telecommunication, Diagnosis & Testing. NOTE: Do NOT replace the mirror for the above condition. SPECIAL TOOLS/EQUIPMENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: USE THE StarSCAN(R) TO PERFORM THIS PROCEDURE. NOTE: The StarSCAN(R) diagnostic scan tool fully supports internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6965 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. The HFM may take up to 20 minutes to time out of the original flash process. A power reset of the HFM, as performed above, may be required. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle data link connector (DLC). 4. Connect the 9097A, Bluetooth UConnect Flash Adapter, to the StarSCAN(R). 5. Power ON the StarSCAN(R). CAUTION: Be careful to select the correct file. 6. Retrieve the old HFM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the HFM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the "Part Number", displayed on the "Flash HFM" screen, for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed HFM calibration. j. Select "Update Controller". Follow the on screen instructions. NOTE: Check your watch, "Sending Update File" may take approximately 17 minutes. Be patient. k. When the HFM update is complete, select "OK". l. Verify that the part number changed at the top of the "Flash HFM" screen. NOTE: Due to the HFM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: USE THE StarSCAN(R) TO PERFORM THIS PROCEDURE. NOTE: For detailed information on the operation of the StarSCAN(R) refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the website under the "Download Center". More recent information and help may also be available at the website under "Training Aids" and also under "Download Center > Frequently Asked Questions". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6966 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. The HFM may take up to 20 minutes to time out of the original flash process. A power reset of the HFM, as performed above, may be required. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle data link connector (DLC). 3. Power ON the StarSCAN(R). 4. Retrieve the old HFM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the HFM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the "Part Number", displayed on the "HFM Flash" screen, for later reference. 5. Insert the StarSCAN(R) Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. a. Select "Download Controller Flash". b. Follow the on screen instructions. 6. At the "Select the method for looking up controller flash updates." screen: a. If the old HFM "Part Number" was recorded in Step # 4, proceed to Step # 7. b. If the old HFM "Part Number" is not known, proceed to Step # 8. 7. Select "Enter part number". a. Follow the on screen instructions. Enter the "Part Number" recorded in Step # 4 when prompted to do so. b. When completed, proceed to Step # 9. 8. Select "Enter YME Information". a. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. b. When completed, proceed to Step # 9. CAUTION: Be careful to select the correct file. 9. Using the mouse highlight the appropriate HFM "Calibration". a. Follow the on screen instructions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6967 10. With the StarSCAN(R) powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) USB port (Fig. 2). 11. Connect the StarSCAN(R) to the vehicle data link connector (if not already connected). 12. Power ON the StarSCAN(R). 13. Download the new HFM calibration (file) to the StarSCAN(R). a. Select "Flash Download". b. Select "Use USB device" and follow the on screen instructions. c. At the "Flash File List" screen, highlight the appropriate ECU (HFM) "Calibration". d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". 14. Disconnect the USB Key and gender changer from the StarSCAN(R) USB port. 15. Connect the gender changer and 9097A, Bluetooth UConnect Flash Adapter, to the StarSCAN(R). 16. Reprogram the vehicle HFM. Using the StarSCAN(R) at the "ECU Overview" screen: a. Select "More Options" b. Select "ECU Flash". c. Highlight the HFM calibration. d. Select "Update Controller". Follow the on screen instructions. NOTE: Check your watch, "Sending Update File" may take approximately 17 minutes. Be patient. e. When the HFM update is complete, select "OK". f. Verify that the part number changed at the top of the "Flash HFM" screen. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Customer Interest: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6968 NOTE: Due to the HFM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-046-06 > Oct > 06 > Audio System - Cell Phone Induced Clicking From Speakers Cellular Phone: All Technical Service Bulletins Audio System - Cell Phone Induced Clicking From Speakers NUMBER: 08-046-06 GROUP: Electrical DATE: October 25, 2006 SUBJECT: Cell Phone Induced Buzz Or Clicking-Like Sound In Radio Speakers OVERVIEW: This bulletin involves a discussion regarding cell phone generated signal interference with the vehicle radio system. MODELS: 2004 (AN) Dakota 2004 - 2007 (DR/DH/D1/DC) Ram Truck 2004 - 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2007 (KA) Nitro 2004 - 2007 (KJ) Liberty 2005 - 2007 (ND) Dakota 2004 - 2006 (TJ) Wrangler 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander SYMPTOM/CONDITION: A customer may experience a buzzing or clicking-like sound coming from the vehicle radio speaker(s). The sound may be heard when the radio is in AM or FM mode. The clicking-like sound may sound like Morse code. DISCUSSION: The hardware construction of certain cell phones may generate frequencies that can interfere with the vehicle radio system. These frequencies may result in buzzing and/or clicking-like sounds in the vehicle radio. GSM type cell phones are more prone to cause this possible interference condition, though other type cell phones may cause similar buzzing and/or clicking-like sounds. This condition can be easily corrected by instructing the customer to move their cell phone away from the immediate area around vehicle radio system (radio, radio amplifier, antenna, antenna lead). DO NOT replace any radio system component in an attempt to address this condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect Cellular Phone: All Technical Service Bulletins Cell Phone - Hands Free Module Will Not Connect NUMBER: 08-014-06 GROUP: Electrical DATE: March 16, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-049-05 DATED SEPTEMBER 01, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED REPAIR PROCEDURES. SUBJECT: Flash: Connect Hands Free Module Fails To Respond Due To Module Lock Up OVERVIEW: This bulletin involves flash reprogramming the Hands Free Module (HFM) module. MODELS: 2006 (DR/DH/D1) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2006 (PT) PT Cruiser 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with UConnect Hands Free Communications (sales code RSP) that were built prior to October 02, 2005 (MDH 1002XX). SYMPTOM/CONDITION: The Hands Free Module (HFM) fails to operate causing the UConnect Hands Free Communications system to not respond when system activation is attempted by the customer. Further diagnosis may reveal that when the StarSCAN(R) scan tool is used to read Diagnostic Trouble Codes (DTC's) the tool indicates that the module is not responding. Other modules on the bus may display loss of communication with the HFM. If the Hands Free Communication system is unresponsive then the HFM may require electronic reset. DIAGNOSIS: Attempt to reset (power reset) the HFM as follows: 1. With the ignition switch in the "Off" position, remove the "Ignition Off Draw" (IOD) fuse and wait 10 seconds. 2. Install the IOD fuse. 3. Turn the ignition to the "On" position (engine not running). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6978 4. After the module is reset, press the "Phone Button" on the rear view mirror to activate the UConnect Hands Free system and to verify proper system operation (Fig. 1). Did the UConnect Hands Free system reset and now operates properly? a. Yes >> Perform Repair Procedure. b. No >> This bulletin does not apply. Further diagnosis is required. Continue diagnosis as needed using the existing diagnostic procedures available in TechCONNECT under: Service Info, 8 Electrical, Navigation/Telecommunication, Diagnosis & Testing. NOTE: Do NOT replace the mirror for the above condition. SPECIAL TOOLS/EQUIPMENT REQUIRED: **REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: USE THE StarSCAN(R) TO PERFORM THIS PROCEDURE. NOTE: The StarSCAN(R) diagnostic scan tool fully supports internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6979 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. The HFM may take up to 20 minutes to time out of the original flash process. A power reset of the HFM, as performed above, may be required. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle data link connector (DLC). 4. Connect the 9097A, Bluetooth UConnect Flash Adapter, to the StarSCAN(R). 5. Power ON the StarSCAN(R). CAUTION: Be careful to select the correct file. 6. Retrieve the old HFM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the HFM in the list of modules. c. Select "More Options" d. Select "ECU Flash". e. Record the "Part Number", displayed on the "Flash HFM" screen, for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed HFM calibration. j. Select "Update Controller". Follow the on screen instructions. NOTE: Check your watch, "Sending Update File" may take approximately 17 minutes. Be patient. k. When the HFM update is complete, select "OK". l. Verify that the part number changed at the top of the "Flash HFM" screen. NOTE: Due to the HFM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. REPAIR PROCEDURE - USING SOFTWARE UPDATE CD TO RETRIEVE THE FLASH FILE: NOTE: USE THE StarSCAN(R) TO PERFORM THIS PROCEDURE. NOTE: For detailed information on the operation of the StarSCAN(R) refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN® Quick Start Networking Guide is also available on the website under the "Download Center". More recent information and help may also be available at the website under "Training Aids" and also under "Download Center > Frequently Asked Questions". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6980 NOTE: If this flash process is interrupted/aborted, the flash should be restarted. The HFM may take up to 20 minutes to time out of the original flash process. A power reset of the HFM, as performed above, may be required. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle data link connector (DLC). 3. Power ON the StarSCAN(R). 4. Retrieve the old HFM part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the HFM in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the "Part Number", displayed on the "HFM Flash" screen, for later reference. 5. Insert the StarSCAN(R) Software Update CD into the TechCONNECT or equivalent PC. The StarSCAN(R) Software Update CD will start automatically. a. Select "Download Controller Flash". b. Follow the on screen instructions. 6. At the "Select the method for looking up controller flash updates." screen: a. If the old HFM "Part Number" was recorded in Step # 4, proceed to Step # 7. b. If the old HFM "Part Number" is not known, proceed to Step # 8. 7. Select "Enter part number". a. Follow the on screen instructions. Enter the "Part Number" recorded in Step # 4 when prompted to do so. b. When completed, proceed to Step # 9. 8. Select "Enter YME Information". a. Follow the on screen instructions. Select "Next" after each step. Select "Finish" after completing the last step. b. When completed, proceed to Step # 9. CAUTION: Be careful to select the correct file. 9. Using the mouse highlight the appropriate HFM "Calibration". a. Follow the on screen instructions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6981 10. With the StarSCAN(R) powered OFF, connect the USB Key and Gender Changer to the StarSCAN(R) USB port (Fig. 2). 11. Connect the StarSCAN(R) to the vehicle data link connector (if not already connected). 12. Power ON the StarSCAN(R). 13. Download the new HFM calibration (file) to the StarSCAN(R). a. Select "Flash Download". b. Select "Use USB device" and follow the on screen instructions. c. At the "Flash File List" screen, highlight the appropriate ECU (HFM) "Calibration". d. Select "Download to Scantool". e. Select "Close" after the download is complete, then select "Back". 14. Disconnect the USB Key and gender changer from the StarSCAN(R) USB port. 15. Connect the gender changer and 9097A, Bluetooth UConnect Flash Adapter, to the StarSCAN(R). 16. Reprogram the vehicle HFM. Using the StarSCAN(R) at the "ECU Overview" screen: a. Select "More Options" b. Select "ECU Flash". c. Highlight the HFM calibration. d. Select "Update Controller". Follow the on screen instructions. NOTE: Check your watch, "Sending Update File" may take approximately 17 minutes. Be patient. e. When the HFM update is complete, select "OK". f. Verify that the part number changed at the top of the "Flash HFM" screen. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-014-06 > Mar > 06 > Cell Phone - Hands Free Module Will Not Connect > Page 6982 NOTE: Due to the HFM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list.** POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-013-05A > Oct > 05 > Cell Phone - UConnect(R) Hands Free Phone Inoperative Cellular Phone: All Technical Service Bulletins Cell Phone - UConnect(R) Hands Free Phone Inoperative NUMBER: 08-013-05 REV. A GROUP: Electrical DATE: October 1, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-013-05, DATED FEBRUARY 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED DISCUSSION. SUBJECT: UConnect Hands Free Phone Inoperative OVERVIEW: This bulletin directs the technician to the appropriate diagnostic path by vehicle line. MODELS: 2005 - 2006 (CS) Pacifica 2005 - 2006 (DR/DH) Ram Truck/Ram Truck HD 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan 2005 - 2006 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with UConnect(TM) Hands Free Communications (sales code RSP). **DISCUSSION: NOTE: Verify that service bulletin 08-049-05 has been performed (where applicable) before proceeding further with this bulletin. NOTE: On CS vehicles with a 05091004AL UConnect Hands Free Module, the scan tool may display a $21 - Bus Busy DTC. This DTC is erroneous and should be ignored. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone: > 08-013-05A > Oct > 05 > Cell Phone - UConnect(R) Hands Free Phone Inoperative > Page 6987 If the UConnect Hands Free Phone is inoperative and if there are no DTC's, perform the existing diagnostic procedure available in TechCONNECT as described in the table. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 08-046-06 > Oct > 06 > Audio System - Cell Phone Induced Clicking From Speakers Cellular Phone: All Technical Service Bulletins Audio System - Cell Phone Induced Clicking From Speakers NUMBER: 08-046-06 GROUP: Electrical DATE: October 25, 2006 SUBJECT: Cell Phone Induced Buzz Or Clicking-Like Sound In Radio Speakers OVERVIEW: This bulletin involves a discussion regarding cell phone generated signal interference with the vehicle radio system. MODELS: 2004 (AN) Dakota 2004 - 2007 (DR/DH/D1/DC) Ram Truck 2004 - 2007 (HB/HG) Durango/Aspen 2007 (JK) Wrangler 2007 (KA) Nitro 2004 - 2007 (KJ) Liberty 2005 - 2007 (ND) Dakota 2004 - 2006 (TJ) Wrangler 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander SYMPTOM/CONDITION: A customer may experience a buzzing or clicking-like sound coming from the vehicle radio speaker(s). The sound may be heard when the radio is in AM or FM mode. The clicking-like sound may sound like Morse code. DISCUSSION: The hardware construction of certain cell phones may generate frequencies that can interfere with the vehicle radio system. These frequencies may result in buzzing and/or clicking-like sounds in the vehicle radio. GSM type cell phones are more prone to cause this possible interference condition, though other type cell phones may cause similar buzzing and/or clicking-like sounds. This condition can be easily corrected by instructing the customer to move their cell phone away from the immediate area around vehicle radio system (radio, radio amplifier, antenna, antenna lead). DO NOT replace any radio system component in an attempt to address this condition. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 08-013-05A > Oct > 05 > Cell Phone - UConnect(R) Hands Free Phone Inoperative Cellular Phone: All Technical Service Bulletins Cell Phone - UConnect(R) Hands Free Phone Inoperative NUMBER: 08-013-05 REV. A GROUP: Electrical DATE: October 1, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-013-05, DATED FEBRUARY 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED DISCUSSION. SUBJECT: UConnect Hands Free Phone Inoperative OVERVIEW: This bulletin directs the technician to the appropriate diagnostic path by vehicle line. MODELS: 2005 - 2006 (CS) Pacifica 2005 - 2006 (DR/DH) Ram Truck/Ram Truck HD 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan 2005 - 2006 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with UConnect(TM) Hands Free Communications (sales code RSP). **DISCUSSION: NOTE: Verify that service bulletin 08-049-05 has been performed (where applicable) before proceeding further with this bulletin. NOTE: On CS vehicles with a 05091004AL UConnect Hands Free Module, the scan tool may display a $21 - Bus Busy DTC. This DTC is erroneous and should be ignored. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cellular Phone: > 08-013-05A > Oct > 05 > Cell Phone - UConnect(R) Hands Free Phone Inoperative > Page 6997 If the UConnect Hands Free Phone is inoperative and if there are no DTC's, perform the existing diagnostic procedure available in TechCONNECT as described in the table. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions Cellular Phone: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7000 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7001 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7002 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7003 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7004 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7005 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7006 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7007 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7008 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7009 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7010 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7011 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7012 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7013 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7014 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7015 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7016 Cellular Phone: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7017 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7018 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Diagram Information and Instructions > Page 7019 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Page 7020 Cellular Phone: Description and Operation The hands-free cellular system on this vehicle uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rearview mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the hands-free system will continue to operate for up to 45 seconds as part of the Accessory Relay Delay function. Thereafter, the call can continue on the hand-held telephone. The system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phone book - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Page 7021 Cellular Phone: Testing and Inspection Part 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Page 7022 Part 2 Any diagnosis of the Telecommunication system should begin with the use of scan tool. WARNING: VEHICLES EQUIPPED WITH AIRBAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Page 7023 Cellular Phone: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel right side end cap. 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect the electrical harness connector and position module. 2. Install and tighten the mounting fasteners. 3. Install the instrument panel right side end cap. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions Collision Avoidance and Parking Assist Systems: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7028 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7029 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7030 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7031 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7032 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7033 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7034 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7035 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7036 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7037 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7038 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7039 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7040 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7041 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7042 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7043 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7044 Collision Avoidance and Parking Assist Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7045 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7046 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7047 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7052 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7053 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7054 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7055 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7056 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7057 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7058 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7059 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7060 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7061 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7062 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7063 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7064 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7065 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7066 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7067 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7068 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7069 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7070 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7071 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7072 Module - Electronic Overhead (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7073 Driver/Vehicle Information Display: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7074 8w-49-3 (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 7075 8w-49-4 (Diesel) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Page 7076 Driver/Vehicle Information Display: Description and Operation An overhead console (1) is available on this vehicle and includes the following components: - Front map/reading lamps (2) - A blue-green vacuum-fluorescent display screen (4) - if equipped with Compass Mini-Trip Computer - Universal transmitter (3) - if equipped - Electronic Overhead Module (EOM) The overhead console assembly is mounted by two snap clips and screws securing it to a molded plastic retainer bracket located above the headliner. The EOM is accessed by removing the overhead console from the bracket and pulling it away from the headliner. COMPASS DISPLAY NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. All the available overhead consoles on this model include Compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle at 5 to 8 kilometers-per-hour (3 to 5 miles-per hour), on level ground in a square shaped pattern. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing procedure may be required to restore proper compass operation. TEMPERATURE DISPLAY All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. Displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the Cab Compartment Node (CCN) over the Controller Area Network (CAN) data bus circuit. The CCN then transfers the temperature information to the EOM for display on the vacuum-fluorescent display screen. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console Driver/Vehicle Information Display: Testing and Inspection Overhead Console NOTE: The temperature, fuel economy, distance to empty and trip odometer are calculated in the Cab Compartment Node (CCN) and transferred to the Electronic Overhead Module (EOM) for display. If the EOM and Vacuum Fluorescent Display (VFD) test OK testing of the CCN and Controller Area Network (CAN) data bus circuit may be necessary. Refer to the proper Diagnostic Procedures Information to test the CCN and CAN data bus circuit. If the problem with the overhead console is an inaccurate or scrambled display, refer to SELFDIAGNOSTIC TEST. See: Self-Diagnostic Test If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Cab Compartment Node (CCN) or Front Control Module (FCM) over the Controller Area Network (CAN) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the Totally Integrated Power Module (TIPM). If the IOD fuse is OK and in place, go to Step 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Totally Integrated Power Module (TIPM), repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST See: Self-Diagnostic Test for further diagnosis of the electronics module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 7079 Driver/Vehicle Information Display: Testing and Inspection Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status". 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EOM will automatically return to normal operation after sixty seconds. The EOM can also be returned to normal operation any time during the test by pressing the STEP, CT, RESET or US/M buttons. The required CAN bus messages are: Dimming message - VIN (Vehicle Identification Number) - Vehicle Speed message - Ignition On Time - Odometer - Trip Odometer - Vehicle Configuration (Model Year, Country and Vehicle Platform) - Fuel Economy - Distance To Empty - Ambient Air Temperature message NOTE: - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7082 Driver/Vehicle Information Display: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screw (3),located in the front of console near the windshield. 3. Using your fingertips, grasp the sides of the overhead console (2) and pull straight down evenly to disengage the two snap clips at the rear of the unit. 4. Lower the overhead console from the headliner far enough to access the wire harness connector (2). 5. Disconnect the roof wire harness connector (2) from the electronic overhead module. 6. Remove the overhead console from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 7083 1. Position the overhead console near the mounting location on the headliner. 2. Reconnect the roof wire harness connector (2) to the electronic overhead module. 3. Align the snap clips on the overhead console housing with their receptacles (3) in the overhead console bracket. 4. Push upward firmly and evenly on the sides of the overhead console housing over the snap clip locations until the snap clips are fully engaged with the receptacles in the overhead console bracket. 5. Install the overhead console retaining screw (3), located in the front of console near the windshield. 6. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams Media System - Monitor/DVD Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams Media System - Monitor/DVD Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation Garage Door Opener Transmitter: Description and Operation The universal transmitter transceiver is integral to the overhead console (7). The only visible component of the universal transmitter are the three transmitter push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 Megahertz (MHz) frequency range for remote operation. The universal transmitter cannot be repaired, and is available for service only as part of the Electronic Overhead Module (EOM). This unit includes the push button switches for both the transmitter and compass mini trip computer, The Vacuum-Fluorescent Display (VFD) and the plastic module case. The universal transmitter receives battery feed through the Ignition Off Draw (IOD) fuse circuit of the vehicle. It operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transmitter radio frequency codes to operate garage door openers, security gates and security lighting. The overhead console display provides visual feedback to the driver, showing which transmitter button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the transmitter system to enter the home. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Garage Door Opener Transmitter: Reading and Clearing Diagnostic Trouble Codes NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. To erase programming from the three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(T) buttons until the indicator light begins to flash-after 20 seconds. Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 7096 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures If both the Transmitter and the compass mini trip computer display are inoperative, refer to testing. If the Universal Transmitter is inoperative, but the compass mini trip computer display is operating normally, refer to Garage Door Opener for instructions on training the Transmitter. Retrain the Transmitter with a known good transmitter as instructed and test the Transmitter operation again. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the universal transmitter assembly. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 7097 Garage Door Opener Transmitter: Programming and Relearning Programming Transmitter Codes Programming Common Transmitter Codes WARNING: - VEHICLE EXHAUST CONTAINS CARBON MONOXIDE, A DANGEROUS GAS. DO NOT RUN THE VEHICLE'S EXHAUST WHILE TRAINING THE TRANSCEIVER. EXHAUST GAS CAN CAUSE SERIOUS INJURY OR DEATH. - YOUR MOTORIZED DOOR OR GATE MAY OPEN AND CLOSE WHILE YOU ARE TRAINING THE UNIVERSAL TRANSCEIVER IF THE VEHICLE IS IN RANGE OF THE MOTORIZED DEVICE. DO NOT TRAIN THE TRANSCEIVER IF PEOPLE OR PETS ARE IN THE PATH OF THE DOOR OR GATE. A MOVING DOOR OR GATE CAN CAUSE SERIOUS INJURY OR DEATH TO PEOPLE AND PETS OR DAMAGE TO OBJECTS. NOTE: When programming a garage door opener, it is advised to park outside the garage. It is also recommended that a new battery be placed in the hand-held transmitter of the device being programmed to HomeLink(R) for quicker training and accurate transmission of the radio-frequency signal. 1. Press and hold the two outer HomeLink(T) buttons, and release only when the indicator light begins to flash (after 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand-held transmitter to the remaining two HomeLink(R) buttons. 2. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink(T) buttons while keeping the indicator light in view. 3. Simultaneously press and hold both the HomeLink(T) button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the "Gate Operator/Canadian Programming" section. 4. The HomeLink(R) indicator light will flash slowly and then rapidly after HomeLink(T) successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. 5. Press and hold the just trained HomeLink(T) button and observe the indicator light. If the indicator light stays on constantly, programming is complete and your device should activate when the HomeLink(T) button is pressed and released. NOTE: To program the remaining two HomeLink(R) buttons, begin with (Programming( step two. Do not repeat step one. If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Programming" STEPs 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). 6. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 7. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 8. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. HomeLink(R) should now activate your rolling code equipped device. NOTE: To program the remaining two HomeLink(T) buttons, begin with "Programming" step two. Do not repeat step one. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for HomeLink(R) to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace "Programming HomeLink(R)" step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. 3. Continue to press and hold the HomeLink(R) button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted by HomeLink(R). (The indicator light will flash slowly and then rapidly.) Proceed with "Programming" step four to complete. Reprogramming Transmitter Codes Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 7098 Reprogramming Basic Transmitter Codes WARNING: - VEHICLE EXHAUST CONTAINS CARBON MONOXIDE, A DANGEROUS GAS. DO NOT RUN THE VEHICLE'S EXHAUST WHILE TRAINING THE TRANSCEIVER. EXHAUST GAS CAN CAUSE SERIOUS INJURY OR DEATH. - YOUR MOTORIZED DOOR OR GATE MAY OPEN AND CLOSE WHILE YOU ARE TRAINING THE UNIVERSAL TRANSCEIVER IF THE VEHICLE IS IN RANGE OF THE MOTORIZED DEVICE. DO NOT TRAIN THE TRANSCEIVER IF PEOPLE OR PETS ARE IN THE PATH OF THE DOOR OR GATE. A MOVING DOOR OR GATE CAN CAUSE SERIOUS INJURY OR DEATH TO PEOPLE AND PETS OR DAMAGE TO OBJECTS. To program a device to HomeLink(R) using a HomeLink(R) button previously trained, follow these steps: 1. Press and hold the desired HomeLink(T) button. Do NOT release the button. 2. The indicator light will begin to flash after 20 seconds. Without releasing the HomeLink(R) button, proceed to STEP 3. 3. Position the end of your hand-held transmitter 1-3 inches (3-8 cm) away from the HomeLink(R) buttons while keeping the indicator light in view. 4. Simultaneously press and hold both the HomeLink(R) button that you want to train and the hand-held transmitter buttons. Do not release the buttons until step 4 has been completed. NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the (Gate Operator/Canadian Programming) section. 5. The HomeLink(R) indicator light will flash slowly and then rapidly after HomeLink(R) successfully receives the frequency signal from the hand-held transmitter. Release both buttons after the indicator light changes from the slow to the rapid flash. 6. Press and hold the just trained HomeLink(R) button and observe the indicator light. If the indicator light stays on constantly, programming is complete and your device should activate when the HomeLink(R) button is pressed and released. NOTE: To program the remaining two HomeLink(R) buttons, begin with (Programming) step two. Do not repeat step one. If the indicator light blinks rapidly for two seconds and then turns to a constant light, continue with "Programming" STEPs 6-8 to complete the programming of a rolling code equipped device (most commonly a garage door opener). 7. At the garage door opener receiver (motor-head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor-head unit. 8. Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.) NOTE: There are 30 seconds in which to initiate step eight. 9. Return to the vehicle and firmly press, hold for two seconds and release the programmed HomeLink(R) button. Repeat the (press/hold/release) sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. HomeLink(R) should now activate your rolling code equipped device. Canadian Programming/Gate Programming Canadian radio-frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for HomeLink(R) to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the 9Programming9 procedures (regardless of where you live), replace (Programming HomeLink(R) step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the (cycling( process to prevent possible overheating. 3. Continue to press and hold the HomeLink(R) button while you press and release every two seconds ("cycle") your hand-held transmitter until the frequency signal has successfully been accepted by HomeLink(R). (The indicator light will flash slowly and then rapidly.) Proceed with "Programming" step four to complete. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions Memory Positioning Systems: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7103 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7104 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7105 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7106 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7107 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7108 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7109 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7110 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7111 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7112 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7113 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7114 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7115 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7116 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7117 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7118 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7119 Memory Positioning Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7120 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7121 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7122 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Lower Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 7127 Motor - Adjustable Pedals (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 7128 Pedal Positioning Motor: Description and Operation MOTOR-ADJUSTABLE PEDALS DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals. Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor (1). The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals. The pedal can be moved rearward (closer to the driver) or forward (away from driver). The brake pedal is moved on its drive screw to a position where the driver feels most comfortable. The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor (1) nor drive mechanism are subject to the mechanical stress of brake or accelerator application. ^ SYSTEM FEATURES: ^ Range of Adjustment: The pedals may be adjusted up to 3 inch (75 mm). ^ Pedal Adjustment Speed: 0.5 in./sec (12.5 mm/sec). ^ Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is activated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 7129 Pedal Positioning Motor: Service and Repair MOTOR-ADJUSTABLE PEDALS REMOVAL 1. Disconnect the negative battery cable. 2. Remove the kneeblocker. 3. Remove the brake light switch and discard. 4. Disconnect the adjustable pedal cables from the brake and accelerator pedals. Also clutch pedal if equipped with a manual transmission. 5. Disconnect the electrical connector. 6. Unclip the cable fasteners to the support. 7. Remove the one mounting bolt (2) for the adjustable pedal motor (1). 8. Remove the adjustable pedal motor (1) with the cables. NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. INSTALLATION NOTE: Adjustable pedal cables are not serviceable. If they need service the adjustable pedal motor with the cables must be installed. 1. Install the adjustable pedal motor (1) with the cables. 2. Install the one mounting bolt (2) for the adjustable pedal motor (1). 3. Clip the cable fasteners to the support. 4. Reconnect the electrical connector. 5. Reconnect the adjustable pedal cables to the brake and accelerator pedals. Also clutch pedal if equipped with a manual transmission. 6. Install the new brake light switch. 7. Install the kneeblocker. 8. Reconnect the negative battery cable. 9. Check for proper operation of the pedals. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 7133 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 7134 Switch - Adjustable Pedals (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 7135 Pedal Positioning Switch: Service and Repair SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Amplifier - Radio C1 (Premium) Amplifier - Radio C2 (Premium) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 7140 Amplifier: Description and Operation The optional Infinity premium speaker system includes a separate Infinity audio power amplifier. The amplifier is an eight-channel unit rated at 368 total output watts. The amplifier is located behind the glove box. If equipped, an additional amplifier rated at 140 watts is located under the center passenger seat. The power amplifier electronically increases the frequency response of the normal audio signal output from the radio amplifier in order to improve the acoustic performance of the speakers. On vehicles equipped with an amplifier, the amplifier section of the radio becomes a pre-amplifier. The amplifier receives audio signal inputs for speaker channels from the radio, then sends amplified audio outputs through six separate channels with dedicated feed and return circuits to the individual speakers. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Instrument Panel Mounted Amplifier: Service and Repair Instrument Panel Mounted REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove glove box. 3. Remove instrument panel center bezel. 4. Remove instrument panel lower right center bezel. 5. Disconnect electrical harness connector (4) from amplifier (2) 6. Remove mounting bolts (3) and amplifier. INSTALLATION 1. Connect electrical harness connector (4) and install amplifier (2). 2. Install and tighten mounting bolts (3). 3. Install instrument panel lower right center bezel. 4. Install instrument panel center bezel. 5. Install glove box. 6. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Instrument Panel Mounted > Page 7143 Amplifier: Service and Repair Center Seat Mounted REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise center seat cushion to access amplifier. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove amplifier. INSTALLATION 1. Connect electrical harness connector and position amplifier. 2. Install and tighten mounting fasteners. 3. Lower center seat. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation Radio/Stereo Noise Filter: Description and Operation Radio noise suppression devices are Installed on this vehicle. Radio Frequency Interference (RFI) and Electromagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing", "hissing," "popping", "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Factory-installed radio noise suppression is accomplished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: - Engine-to-body ground strap - This length of braided ground strap has an eyelet terminal connector crimped to each end. One end is secured to the engine cylinder head(s). The other is secured to the plenum at the exhaust heat shield forward/outer attaching stud. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and Electro-Magnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Bed to Cab Radio/Stereo Noise Filter: Service and Repair Bed to Cab REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts and strap. INSTALLATION 1. Install the ground strap (3) and mounting fasteners (4). 2. Tighten mounting fasteners. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Bed to Cab > Page 7150 Radio/Stereo Noise Filter: Service and Repair Engine to Heat Shield REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the attaching bolts (2) from the cylinder heads. 3. Remove nut (3) from heat shield (1) and remove strap (2). INSTALLATION 1. Install the mounting fastener (3) and ground strap (2) to the heat shield (1). 2. Tighten mounting fastener. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Bed to Cab > Page 7151 3. Install the retaining bolt and ground strap to the engine cylinder heads. 4. Tighten the retaining bolts. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7155 Remote Switch: Diagrams Switch-Remote Radio - Left Switch-Remote Radio - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7156 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7157 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams refer to appropriate wiring information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7158 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Speaker: Customer Interest Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 7167 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON Speaker: Customer Interest Audio System - Door Area Buzzing Sound With Audio ON NUMBER: 23-018-06 GROUP: Body DATE: May 05, 2006 SUBJECT: Speaker Buzz OVERVIEW: This bulletin involves adding insulating tape to the inner door and door trim panel. MODELS: 2006 (DR/DH/D1) Ram Truck SYMPTOM/CONDITION: Customers may experience a buzzing sound coming from the door area when the radio is on. DIAGNOSIS: Operate the radio with the bass and treble in the center position. The volume should be at the # 20 position with music playing. If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in Section 23 of the 2006 Ram Truck Service Information on TechCONNECT, remove the door trim panel on the door that has the condition. 2. Remove the speaker from the inner door panel but do not disconnect the speaker wires. 3. Operate the radio as described earlier while holding the speaker by the magnet in your hand, Listen from the side of the speaker for the buzzing sound. If the sound is coming from the speaker. The speaker requires replacing and the remainder of this procedure can be skipped. If the sound is not present, proceed to step 4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7172 4. Apply three 6 inch pieces of foam tape, p/n 04318028 to the area shown on the inner door panel sheet metal. (Fig. 1). 5. Install the water shield. 6. Install the speaker on to the inner door panel. 7. Carefully pry map pocket on the lower door trim panel away from the support post on the door trim panel as shown (Fig. 2). 8. Apply a 1 inch by 1 inch square of felt tape, p/n 05019055AA to the support post to isolate the support post from the map pocket panel (Fig. 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7173 9. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Speaker: All Technical Service Bulletins Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 7179 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON Speaker: All Technical Service Bulletins Audio System - Door Area Buzzing Sound With Audio ON NUMBER: 23-018-06 GROUP: Body DATE: May 05, 2006 SUBJECT: Speaker Buzz OVERVIEW: This bulletin involves adding insulating tape to the inner door and door trim panel. MODELS: 2006 (DR/DH/D1) Ram Truck SYMPTOM/CONDITION: Customers may experience a buzzing sound coming from the door area when the radio is on. DIAGNOSIS: Operate the radio with the bass and treble in the center position. The volume should be at the # 20 position with music playing. If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in Section 23 of the 2006 Ram Truck Service Information on TechCONNECT, remove the door trim panel on the door that has the condition. 2. Remove the speaker from the inner door panel but do not disconnect the speaker wires. 3. Operate the radio as described earlier while holding the speaker by the magnet in your hand, Listen from the side of the speaker for the buzzing sound. If the sound is coming from the speaker. The speaker requires replacing and the remainder of this procedure can be skipped. If the sound is not present, proceed to step 4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7184 4. Apply three 6 inch pieces of foam tape, p/n 04318028 to the area shown on the inner door panel sheet metal. (Fig. 1). 5. Install the water shield. 6. Install the speaker on to the inner door panel. 7. Carefully pry map pocket on the lower door trim panel away from the support post on the door trim panel as shown (Fig. 2). 8. Apply a 1 inch by 1 inch square of felt tape, p/n 05019055AA to the support post to isolate the support post from the map pocket panel (Fig. 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7185 9. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7186 Speaker: Diagrams Speaker-Instrument Panel - Center (SLT/SLT+) Speaker-Instrument Panel - Left (SLT/SLT+) Speaker-Instrument Panel - Right (SLT/SLT+) Speaker - Left Front Door Speaker - Left Rear Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7187 Speaker - Right Front Door Speaker - Right Rear Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7188 Speaker: Description and Operation STANDARD The standard equipment speaker system includes speakers in four locations. One 15.2 X 22.8 centimeter (6 X 9 inch) full-range speaker is located in each front door. There is also one full-range 13.3 centimeter (5.25 inch) diameter full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). PREMIUM The optional premium speaker system features eleven Premium model speakers in seven locations. Each of the standard speakers is replaced with Premium model speakers. One 8.8 centimeter (3.50 inch) diameter speaker is located on each end of the instrument panel top pad. One 6.3 centimeter (2.50 inch) diameter speaker is located in the center of the instrument panel top pad. One 15.2 X 22.8 centimeter (6 X 9 inch) Premium speaker is located in each front door. There is also one coaxial 13.3 centimeter (5.25 inch) diameter Premium full-range speaker located in each rear door (quad cab) or B-pillar (regular cab). The premium speaker system also includes a power amplifier mounted behind the glove box. The total available power of the premium speaker system is 368 watts. If equipped, a 25.4 centimeter (10 inch) subwoofer is located behind the center passenger seat along with a amplifier (rated at 150 watts) located under the center passenger seat. The total available power if equipped with the subwoofer and second power amplifier is 518 watts. Two wires connected to each speaker, one feed circuit (+) and one return circuit (-), allow the audio output signal electrical current to flow through the voice coil. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 7189 Speaker: Testing and Inspection Any diagnosis of the Audio system should begin with the use of a scan tool. Refer to the appropriate wiring information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CAUTION: The speaker output of the radio is a floating ground system. Do not allow any speaker lead to short to ground, as damage to the radio and/or amplifier may result. 1. If all speakers are inoperative, check the fuses in the Totally Integrated Power Module (TIPM). If OK, go to Step (2). If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the TIPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with an amplifier, remove the radio receiver. If vehicle is equipped with an amplifier, disconnect wire harness connector at output side of amplifier. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7192 Speaker: Service and Repair Instrument Panel Center Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7193 Speaker: Service and Repair Instrument Panel End Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7194 Speaker: Service and Repair Rear Cab Side Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7195 Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove front door trim panel. 3. Remove mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install front door trim panel. 4. Connect battery negative cable. Instrument Panel Center Speaker REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7196 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Instrument Panel End Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7197 2. Remove instrument panel top cover. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. Rear Cab Side Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove B-pillar lower trim. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7198 1. Connect electrical harness connector and install speaker. 2. Install and tighten mounting fasteners. 3. Install B-pillar lower trim. 4. Connect battery negative cable. Rear Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove rear door trim panel. 3. Remove speaker mounting fasteners. 4. Disconnect electrical harness connector and remove speaker. INSTALLATION 1. Connect electrical harness connector and install speaker. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7199 2. Install and tighten mounting fasteners. 3. Install rear door trim panel. 4. Connect battery negative cable. Subwoofer - Regular Cab REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove mounting fasteners to subwoofer housing. 3. Disconnect electrical harness connector. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7200 4. Remove subwoofer from vehicle. INSTALLATION 1. Position subwoofer housing into the vehicle. 2. Connect electrical harness connector. 3. Install mounting fasteners. 4. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Front Door Speaker > Page 7201 Subwoofer - Quad Cab REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Raise left rear seat to access subwoofer. 3. Disconnect electrical harness connector. 4. Remove mounting fasteners and remove subwoofer. INSTALLATION 1. Position subwoofer to vehicle. 2. Connect electrical harness connector. 3. Install and tighten mounting fasteners. 4. Lower seat. 5. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation PCM OUTPUT The 5 pin, 12 volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12 volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut down, meaning the 12 volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7209 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 7210 Module - Sentry Key Remote Entry Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, refer to Keyless Entry Transmitter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 7213 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS) and is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. The Sentry Key REmote Entry Module (SKREEM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC), the Powertrain Control Module (PCM)/Engine Control Module (ECM), the Gateway module (SRT10 vehicles with a hybrid bus only) and the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then listens for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends a valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 7214 SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator status messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator status message from the SKREEM tells the EMIC to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator status messages to the EMIC to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM detects an invalid key or if a key transponder- related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The SKREEM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Description and Operation > Page 7215 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry Keyless Entry Module: Service and Repair Module-Remote Keyless Entry REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7218 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7219 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7220 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7221 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 7225 Module - Hands Free Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 7230 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 7231 Switch - Adjustable Pedals (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 7232 Pedal Positioning Switch: Service and Repair SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations Steering Wheel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7236 Remote Switch: Diagrams Switch-Remote Radio - Left Switch-Remote Radio - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7237 Remote Switch: Description and Operation Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Totally Integrated Power Module (TIPM) through the clockspring. The TIPM sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the TIPM senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Programmable Communication Interface (PCI) data bus network to the radio receiver. The electronic circuitry within the radio receiver is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. For diagnosis of the TIPM or the PCI data bus, the use of a scan tool and the proper Diagnostic Procedures information is recommended. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7238 Remote Switch: Testing and Inspection Any diagnosis of the Audio system should begin with the use of scan tool. For complete circuit diagrams refer to appropriate wiring information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test Table 3. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test chart. If the remote radio switch resistances check OK, go to Step 4. If not OK, replace the faulty switch. 4. Connect the battery negative cable. Turn the ignition switch to the On position. Check for 5 volts at the radio control mux circuit cavities of the steering wheel wire harness connectors for both remote radio switches. If OK, go to Step 5. If not OK, repair the open or shorted radio control mux circuit to the Totally Integrated Power Module (TIPM) as required. 5. Disconnect and isolate the battery negative cable. Disconnect the 22-way instrument panel wire harness connector from the TIPM. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and a good ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted remote radio switch ground circuit to the TIPM as required. 6. Check for continuity between the remote radio switch ground circuit cavities of the steering wheel wire harness connectors for both remote radio switches and the 22-way instrument panel wire harness connector for the TIPM. There should be continuity. If OK, test the TIPM and the PCI data bus. If not OK, repair the open remote radio switch ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Page 7239 Remote Switch: Service and Repair WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag. 3. Remove the speed control switches (2). 4. Unplug the wire harness connector from the remote radio switch (1). 5. Depress the tabs on each side of each switch and push the switch through the rear steering wheel cover. INSTALLATION 1. Install remote radio switch (1) to the steering wheel. 2. Connect the wire harness to the remote radio switch. 3. Install the speed control switches (2). 4. Install the driver airbag. 5. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK ASSEMBLY REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Page 7244 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 N.m (50 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 8w-54-3 (Except Box) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 8w-54-4 (Except Add On Trailer Tow) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 8w-54-5 (Add On Trailer Tow) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 8w-54-6 (Add On Trailer Tow) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 7274 Trailer Connector: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Page 7275 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 N.m (17 in. lbs.). 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7279 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft.lbs.). 3. Connect all wire harness support push pins. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Page 7280 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft.lbs.). 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7285 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7286 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7287 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7288 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7289 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7290 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7291 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7292 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7293 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7294 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7295 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7296 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7297 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7298 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7299 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7300 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7301 Trailer Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7302 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7303 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7304 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 7305 Trailer Lamps: Connector Views Wiring-Trailer Tow (Box Off) - 1 Way Wiring Trailer Tow 4 - Way Wiring-Trailer Tow 7 - Way Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring Trailer Lamps: Description and Operation Trailer Tow Wiring In addition to the trailer tow wiring provisions, the TIPM in all vehicles includes trailer tow battery, park lamp, and both right and left stop/turn feed output provisions. When the TIPM receives the appropriate inputs for normal park, turn signal, hazard warning or brake lamp operation, it responds by providing battery voltage through the appropriate trailer tow wiring feed circuits to synchronize the illumination and flash rate of the trailer park, brake and turn signal lamps with those of the tow vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring > Page 7308 Trailer Lamps: Description and Operation Wiring-Trailer Tow The rear body wire harness on the rear frame (1) of all vehicles is equipped with a take out with a standard, light-duty 4-pin trailer tow connector (2) that is secured to the top of the trailer hitch platform (4) behind the rear bumper. Vehicles equipped with an optional factory-installed trailer towing package have a second take out with a connector (3) that plugs into a receptacle in the back of a heavy duty, sealed, 7-pin trailer tow connector that is located near the center of the rear bumper. Vehicles equipped with the trailer tow package also include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (1) that are stored in the glove box (2) when the vehicle is shipped from the factory. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The standard 4-pin trailer tow connector contains the following vehicle circuits: park/tail lamps, left stop/turn lamp, right stop/turn lamp, and ground. The optional trailer towing package 7-way connector contains the same circuits as the 4-pin connector plus the following additional circuits: backup lamp, trailer battery and electric brake. If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. Refer to the appropriate wiring information. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the truck battery while the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the vehicle glove box for type, location, and ampere rating of the fuse or circuit breaker. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 7312 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7317 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7318 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7319 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7320 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7321 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7322 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7323 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7324 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7325 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7326 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7327 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7328 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7329 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7330 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7331 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7332 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7333 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7334 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7335 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7336 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7337 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7338 8w-54-3 (Except Box) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7339 8w-54-4 (Except Add On Trailer Tow) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7340 8w-54-5 (Add On Trailer Tow) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 7341 8w-54-6 (Add On Trailer Tow) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 7342 Trailer Connector: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach behind the center of the rear bumper to access and disconnect the connector (2) of the body wire harness from the 7-way trailer tow connector (1). 3. Remove the four screws (3) that secure the 7-way trailer tow connector (2) to the tapping plate (4) behind the rear bumper. 4. Remove the 7-way trailer tow connector from the face of the rear bumper and the tapping plate from behind the rear bumper. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Page 7343 1. Position the 7-way trailer tow connector (2) into the mounting hole on the face of the rear bumper (1). 2. Position the tapping plate (4) over the 7-way trailer tow connector on the back of the rear bumper. 3. Install and tighten the four screws (3) that secure the 7-way trailer tow connector to the tapping plate. Tighten the screws to 2 N.m (17 in. lbs.). 4. Reach behind the center of the rear bumper to access and reconnect the connector (2) of the body wire harness to the 7-way trailer tow connector (1). 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 7348 Module - Hands Free Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Component Information > Testing and Inspection Winch: Testing and Inspection Relay Test 1. Disconnect the red (+) battery cable (1). 2. Remove the winch assembly (2) as necessary to gain access to the relay pack and cover. 3. Disconnect the three cables connected to the motor on the studs marked F1 (2) , F2 (1) and A (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Component Information > Testing and Inspection > Page 7352 4. Remove the nut and disconnect the terminal wire (1). 1. Measure the resistance between the two large studs on relay #1. 2. The resistance should be greater than 1 megaohm. 3. Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2). 4. Measure the resistance between the two large studs on relay #1. 5. The resistance should be less than 1 ohm. 6. Remove the nut and disconnect the terminal wire (1). 1. Measure the resistance between the two large studs on relay #2. 2. The resistance should be greater than 1 megaohm. 3. Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2). 4. Measure the resistance between the two large studs on relay #2. 5. The resistance should be less than 1 ohm. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Accessories and Optional Equipment > Winch > Component Information > Testing and Inspection > Page 7353 6. Remove the nut and disconnect the terminal wire (1). 1. Measure the resistance between the two large studs on relay #3. 2. The resistance should be greater than 1 megaohm. 3. Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2). 4. Measure the resistance between the two large studs on relay #3. 5. The resistance should be less than 1 ohm. 6. Remove the nut and disconnect the terminal wire (1). 1. Measure the resistance between the two large studs on relay #4. 2. The resistance should be greater than 1 megaohm. 3. Apply 12 volts to the small terminal (1) and apply ground to the small terminal (2). 4. Measure the resistance between the two large studs on relay #4. 5. The resistance should be less than 1 ohm. 6. If the resistance across any of the relays doesn't go from open to closed (megaohm to tenths) then the relay is bad and needs to be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank Body Control Module: Customer Interest Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 7364 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 7365 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-021-06A > Oct > 06 > Electrical - Electrical Malfunctions/DTC's Set/No Crank > Page 7366 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical Electrical Malfunctions/DTC's Set/No Crank Body Control Module: All Technical Service Bulletins Electrical - Electrical Malfunctions/DTC's Set/No Crank NUMBER: 08-021-06 REV. A GROUP: Electrical DATE: October 13, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-021-06, DATED MAY 10, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: TIPM Flash - DTC's Indicating Short Circuits In The Wiring On The Trailer Or No Engine Crank With DTC P1277 - Starter Control Circuit 2 Low OVERVIEW: This bulletin involves a discussion and reprogramming of the Totally Integrated Power Module (TIPM). MODELS: 2006 (DR/DH/D1) Ram Truck NOTE: This bulletin applies to vehicles built prior to April 03, 2006 (MDH 0403XX). SYMPTOM/CONDITION: Customer may experience any of the following TIPM Diagnostic Trouble Codes (DTC's): B166B - Left Trailer Tow Lamp Control Circuit Low. Trailer harness left lamp circuit is shorted to ground. B166C - Left Trailer Tow Lamp Control Circuit High. Trailer harness left lamp circuit is shorted to battery voltage. B178C - Left Trailer Tow Lamp Control Circuit Over Current. Trailer harness left lamp circuit is intermittently grounding. B166F - Right Trailer Tow Lamp Control Circuit Low. Trailer harness right lamp circuit is shorted to ground. B1670 - Right Trailer Tow Lamp Control Circuit High. Trailer harness right lamp circuit is shorted to battery voltage. B166E - Right Trailer Tow Lamp Control Circuit Over Current. Trailer harness right lamp circuit is intermittently grounding. B1667 - Back Up Lamp Feed Low. Trailer harness back up circuit is shorted to ground. B2215 - Front Control Module Internal (TIPM). An internal fault code counter has exceeded its limit of 250 counts and one or more electrical outputs controlled by the TIPM have been disabled. P1277 - Starter Control Circuit 2 Low (TIPM). The output feed current to the starter solenoid has exceeded the upper current limit of 75 amps. This may result in a no-crank condition. DISCUSSION: DTC's B1667, B166B, B166E, B166F, B178C and B2215: 1. These DTC's indicate that a (hard or intermittent) short circuit to GROUND exists in the wiring of one or more of the TRAILER electrical harness circuits. 2. The TIPM retries the output on each ignition cycle or request (brake or turn signal activation) in an attempt to enable the output in case the fault is intermittent. 3. DTC's B1667, B166B, B166E, B166F, and B178C may occur individually or in combination with each other. 4. For the two over current DTC's, B166E and B178C, the fault is set when the TIPM has detected electrical loads on the circuit greater than 15 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical Electrical Malfunctions/DTC's Set/No Crank > Page 7372 amps. 5. If DTC B2215 is also present with one of more of the above DTC's, then this fault code indicates that the 11PM has detected the faulted condition (short) on one or more of the trailer circuits more than 250 times. When detected more than 250 times, the TIPM disables the electrical output (turns off) to the respective faulty trailer circuit to protect that circuit and the system. 6. Short circuits can be intermittent and will require diagnosis and repair of the trailer wire harness. 7. Once the faulty circuit has been repaired, the dealer must use a scan tool to enable the respective trailer circuit that was previously been turned off (disabled) due to DTC B2215. 8. The new TIPM software raises the TIPM circuit trigger point from 15 amps. to 20 amps. DTC's B166C and B1670: 1. These DTC's indicate that a short circuit to BATTERY voltage (12 volts) exists in the wiring of one of the TRAILER electrical harness circuits. DTC B2215 - Front Control Module (TIPM): 1. This fault code occurs when the TIPM detects a short (to ground or to battery) on one of the trailer circuits more than 250 times. 2. When B2215 is present with one of the above trailer circuit faults the TIPM will turn off (disable) the respective faulty trailer circuit or circuits. 3. This internal fault DOES NOT mean that the TIPM module is defective. 4. The TIPM memory can be cleared, this action will turn on a previously disabled trailer circuit. If possible, the fault in the circuit should be repaired first before clearing the TIPM memory. 5. DO NOT replace the TIPM without first attempting to clear the 11PM memory. 6. The dealer will need a scan tool to clear the TIPM memory. 7. If one or more of the TIPM outputs are disabled due to one of these conditions, normal operation can be restored a maximum of five (5) times. 8. The TIPM will be rendered inoperative on the sixth attempt to clear the TIPM memory. At this point the 11PM must be replaced. The DTC(s) that indicates the problem and DTC 2215 will both remain ACTIVE. Neither fault code will can be cleared at this point. DTC P1277 - Starter Control Circuit 2 Low (TIPM): 1. The TIPM monitors the output current to the starter solenoid for over-current conditions. 2. The DTC is set when the output current to starter solenoid exceeds 75 amps. 3. On trucks equipped with a diesel engine, there may be times in cold climates when it is normal for the starter solenoid current to exceed 75 amps. 4. If DTC B2215 is present in addition to DTC P1277, then a starter solenoid circuit over-current condition has been detected by the TIPM module more than 250 times. At this point, the circuit to the starter solenoid is turned off until the TIPM memory is cleared. 5. The new TIPM software raises the TIPM current trigger point for DTC P1277 from 75 amps. to 100 amps. DIAGNOSIS: If any of the DTC's listed above are present, perform the Repair Procedure. NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical Electrical Malfunctions/DTC's Set/No Crank > Page 7373 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (TIPM flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the TIPMCGW in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash TIPMCGW" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". 13. Highlight the listed calibration. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-021-06A > Oct > 06 > Electrical Electrical Malfunctions/DTC's Set/No Crank > Page 7374 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash TIPMCGW" screen has updated to the new part number. NOTE: Due to the TIPMCGW programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Diagnostic Trouble Code Descriptions Body Control Module: Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL ST/SLT/SLT+ 1. Remove the two screws (4) at each trailing edge of the fascia. 2. Remove the four push pin fasteners (5) from the upper edge of the close out panel. 3. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 4. Using a trim stick or equivalent, carefully remove the step pad (1). 5. Remove and discard the four push pin fasteners (5) and remove the fascia. SPORT 1. Raise and support the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 7382 2. Remove the three screws (3) at each trailing edge of the fascia. 3. Remove the five lower screws (8). 4. Remove and discard the four upper push pins (7). 5. Using a trim stick (special tool #C-4755) or equivalent, carefully release the six lower clips and remove the close out panel. 6. Using a trim stick or equivalent, carefully remove the step pad (1). 7. Spread the fascia (2) out at the wheels and remove from the vehicle. INSTALLATION ST/SLT/SLT+ NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Install the fascia. 2. Position the close out panel and seat the 6 lower clips fully. 3. Install four new upper push pin fasteners (5). 4. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 5. Align the fascia to the fender with a 19 mm (0.75 inch) gap and install the two screws at each trailing edge of the fascia. SPORT Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 7383 NOTE: The left and right inboard bumper to bracket attachments must be secured before installing the fascia and step pad. 1. Position the fascia (2) onto the bumper. 2. Position the step pad (1) onto the fascia (2) and fully seat the attachment clips. 3. Install four new upper push pin fasteners (7). 4. Install the five lower screws (8). 5. Install the three screws (3) at each trailing edge of the fascia. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair Rear Bumper: Service and Repair REAR BUMPER REMOVAL 1. Raise and support the vehicle. 2. Remove the license plate. 3. Remove the bolts behind the plate. 4. Disconnect the license plate light electrical connectors. 5. Disconnect the trailer light connector electrical connection (if equipped). 6. Remove the two bolts along the front upper edge of the bumper near the frame tips. 7. Support the bumper with a suitable lifting device. 8. Remove the bolts attaching the bumper support brackets (4) to the trailer hitch (1). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > System Information > Service and Repair > Page 7387 1. Align the holes in the bumpers to the trailer hitch pins and install the bumper. 2. Loosely install the hitch bolts (2) in the support bracket (4). 3. Install the front upper edge to the trailer hitch bolts (2) and tighten to 54 N.m (40 ft.lbs.). 4. Install the license plate reinforcement to hitch bolts (2) and tighten to 54 N.m (40 ft.lbs.). 5. Tighten the left bumper bracket bolts (3) to 54 N.m (40 ft.lbs.). 6. Tighten the right bumper bracket bolts (3) to 54 N.m (40 ft.lbs.). 7. Connect the trailer light connector electrical connection (if equipped). 8. Connect the license plate light electrical connectors. 9. Install the license plate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair BODY VENT REMOVAL 1. Remove the rear cab trim panel, Refer to Trim Panel. 2. Disengage the retaining tabs (1) that secure the body vent (3) to the cab back panel (2). 3. Remove the vent through the opening in the cab back panel. INSTALLATION 1. Position the body vent (3) into the opening of the cab back panel (2). 2. Install the body vent into the cab back panel and fully engage the retaining tabs (1). 3. Install the rear cab trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the door glass. 3. If equipped, disconnect the exterior handle wire lead (7) from the door wire harness connector (3). 4. Disconnect the actuator rods (6 and 8) for the door latch (5) from the exterior handle (1). 5. Remove the two nuts (2) that secure the exterior handle to the door (4) and remove the handle. INSTALLATION 1. Position the exterior handle (1) into the door (4). 2. Install the two nuts (2) that secure the exterior handle to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rods (6 and 8) for the door latch (5) to the exterior handle. 4. If equipped, connect the exterior handle wire lead (7) to the door wire harness connector (3). 5. Install the door glass. 6. Reconnect the negative battery cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair INTERIOR HANDLE ACTUATOR REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from interior door handle actuator (5) and the door latch (2), if necessary. 3. Remove the two nuts (4) that secure the interior door handle actuator to the door (1) and remove the actuator. INSTALLATION 1. Position the interior door handle actuator (5) onto the door (1). 2. Install the two nuts (4) that secure the interior door handle actuator to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (3) to the interior door handle actuator and the door latch (2), if removed. 4. Reposition the waterdam and install the door trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7413 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7414 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7420 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7421 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7422 Front Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7423 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7424 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7425 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > Page 7426 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Page 7427 Front Door Hinge: Service and Repair HINGE REMOVAL 1. Remove the door. 2. Using a grease pencil or equivalent, mark the hinge location and remove the bolts (3) and (4). INSTALLATION NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Install the hinges and bolts. 2. Tighten the upper hinge bolt (1) to hinge pillar to 28 N.m (21 ft.lbs.). 3. Tighten the lower hinge bolt (2) to hinge pillar to 28 N.m (21 ft.lbs.). 4. Tighten the remaining hinge to hinge pillar bolts (3) and (4) to 28 N.m (21 ft.lbs.). 5. Install the door. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams Front Door Latch: Diagrams Latch-Door - Driver (Base) Latch-Door - Driver (Power Locks) Latch-Door - Passenger (Power Locks) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7431 Front Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 N.m (30 in.lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7432 Front Door Latch: Service and Repair LATCH REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (3) from the door latch (2) and the interior door handle actuator (5) and remove the rod. 3. Disconnect the door wire harness connector (2) from the door latch (3). 4. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Diagrams > Page 7433 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the actuator rod (3) to the door latch (2) and the interior door handle actuator (5). 5. Reposition the waterdam to the door (1) and install the door trim panel. 6. If necessary, adjust the latch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Front Door Panel: Customer Interest Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 7442 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON Front Door Panel: Customer Interest Audio System - Door Area Buzzing Sound With Audio ON NUMBER: 23-018-06 GROUP: Body DATE: May 05, 2006 SUBJECT: Speaker Buzz OVERVIEW: This bulletin involves adding insulating tape to the inner door and door trim panel. MODELS: 2006 (DR/DH/D1) Ram Truck SYMPTOM/CONDITION: Customers may experience a buzzing sound coming from the door area when the radio is on. DIAGNOSIS: Operate the radio with the bass and treble in the center position. The volume should be at the # 20 position with music playing. If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in Section 23 of the 2006 Ram Truck Service Information on TechCONNECT, remove the door trim panel on the door that has the condition. 2. Remove the speaker from the inner door panel but do not disconnect the speaker wires. 3. Operate the radio as described earlier while holding the speaker by the magnet in your hand, Listen from the side of the speaker for the buzzing sound. If the sound is coming from the speaker. The speaker requires replacing and the remainder of this procedure can be skipped. If the sound is not present, proceed to step 4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7447 4. Apply three 6 inch pieces of foam tape, p/n 04318028 to the area shown on the inner door panel sheet metal. (Fig. 1). 5. Install the water shield. 6. Install the speaker on to the inner door panel. 7. Carefully pry map pocket on the lower door trim panel away from the support post on the door trim panel as shown (Fig. 2). 8. Apply a 1 inch by 1 inch square of felt tape, p/n 05019055AA to the support post to isolate the support post from the map pocket panel (Fig. 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest for Front Door Panel: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7448 9. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds Front Door Panel: All Technical Service Bulletins Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-028-07A > Jul > 07 > Audio System - Front Door Speaker Buzzing Sounds > Page 7454 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON Front Door Panel: All Technical Service Bulletins Audio System - Door Area Buzzing Sound With Audio ON NUMBER: 23-018-06 GROUP: Body DATE: May 05, 2006 SUBJECT: Speaker Buzz OVERVIEW: This bulletin involves adding insulating tape to the inner door and door trim panel. MODELS: 2006 (DR/DH/D1) Ram Truck SYMPTOM/CONDITION: Customers may experience a buzzing sound coming from the door area when the radio is on. DIAGNOSIS: Operate the radio with the bass and treble in the center position. The volume should be at the # 20 position with music playing. If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in Section 23 of the 2006 Ram Truck Service Information on TechCONNECT, remove the door trim panel on the door that has the condition. 2. Remove the speaker from the inner door panel but do not disconnect the speaker wires. 3. Operate the radio as described earlier while holding the speaker by the magnet in your hand, Listen from the side of the speaker for the buzzing sound. If the sound is coming from the speaker. The speaker requires replacing and the remainder of this procedure can be skipped. If the sound is not present, proceed to step 4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7459 4. Apply three 6 inch pieces of foam tape, p/n 04318028 to the area shown on the inner door panel sheet metal. (Fig. 1). 5. Install the water shield. 6. Install the speaker on to the inner door panel. 7. Carefully pry map pocket on the lower door trim panel away from the support post on the door trim panel as shown (Fig. 2). 8. Apply a 1 inch by 1 inch square of felt tape, p/n 05019055AA to the support post to isolate the support post from the map pocket panel (Fig. 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 23-018-06 > May > 06 > Audio System - Door Area Buzzing Sound With Audio ON > Page 7460 9. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7461 Front Door Panel: By Symptom Technical Service Bulletin # 23-028-07A Date: 070720 Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7462 panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-06 Date: 060505 Audio System - Door Area Buzzing Sound With Audio ON Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7463 NUMBER: 23-018-06 GROUP: Body DATE: May 05, 2006 SUBJECT: Speaker Buzz OVERVIEW: This bulletin involves adding insulating tape to the inner door and door trim panel. MODELS: 2006 (DR/DH/D1) Ram Truck SYMPTOM/CONDITION: Customers may experience a buzzing sound coming from the door area when the radio is on. DIAGNOSIS: Operate the radio with the bass and treble in the center position. The volume should be at the # 20 position with music playing. If the condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Using the procedures outlined in Section 23 of the 2006 Ram Truck Service Information on TechCONNECT, remove the door trim panel on the door that has the condition. 2. Remove the speaker from the inner door panel but do not disconnect the speaker wires. 3. Operate the radio as described earlier while holding the speaker by the magnet in your hand, Listen from the side of the speaker for the buzzing sound. If the sound is coming from the speaker. The speaker requires replacing and the remainder of this procedure can be skipped. If the sound is not present, proceed to step 4. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7464 4. Apply three 6 inch pieces of foam tape, p/n 04318028 to the area shown on the inner door panel sheet metal. (Fig. 1). 5. Install the water shield. 6. Install the speaker on to the inner door panel. 7. Carefully pry map pocket on the lower door trim panel away from the support post on the door trim panel as shown (Fig. 2). 8. Apply a 1 inch by 1 inch square of felt tape, p/n 05019055AA to the support post to isolate the support post from the map pocket panel (Fig. 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7465 9. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-028-07A Date: 070720 Audio System - Front Door Speaker Buzzing Sounds NUMBER: 23-028-07 REV. A GROUP: Body DATE: July 20, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-028-07, DATED JULY 12, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND ADDS 2006 MODEL YEAR. SUBJECT: Buzz-Like Sound From Front Door Speaker Area When Radio Is On OVERVIEW: This bulletin involves determining the source of the buzz-like sound and making appropriate repairs. MODELS: **2006** - 2007 (DR/DH/D1/DC) Ram Truck (1500/2500/3500) SYMPTOM/CONDITION: The customer may a experience a buzz-like sound coming from the left and/or right front door when the radio is on. This sound in question will come from the interior door trim panel, in the area where the radio speaker is mounted. This condition may be misdiagnosed as a bad radio speaker. The actual cause may be the interface between the door trim panel sound insulation and the door water shield. DIAGNOSIS: 1. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 2. Turn the radio on. Set the bass and treble settings on the radio to their "centered position and fade the sound to the suspect door(s). 3. Adjust the radio volume to the # 20 position with music playing. 4. Determine if the buzz-like sound condition is present in the suspect front door(s). 5. Turn the ignition switch to the "OFF" position. 6. If the condition is present perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7466 PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the interior trim panel on the affected door. Refer to TechCONNECT for detailed service procedures. Select the "Service Info tab > 23-Body > Door - Front> Trim Panel > Removal and Installation. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are INTEGRAL to the door trim panel. DO NOT pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 2. Remove the front door radio speaker from its mounting to the door. Do not disconnect the electrical connection to the speaker. 3. Turn the ignition switch to the "ON" position. DO NOT start the vehicle engine. 4. Hold the radio speaker by its magnet in your hand. 5. Operate the radio as described above in the Diagnosis section 6. Listen from the side of the speaker for the buzz-like sound. 7. Is the buzz-like sound coming from the speaker? a. If YES >>> then turn the ignition switch to the "OFF" position and replace the radio speaker. Proceed to the next step. b. If NO >>> then turn the ignition switch to the "OFF" position and install the radio speaker to the inner door panel. Proceed to the next step. 8. Loose fit the new sound insulation to the back side of the front door trim panel. DO NOT remove the original sound insulation from the door trim panel. The new sound insulation will install over the original door sound insulation and extends to the bottom of the door. Note the pieces of adhesive tape on the new sound insulation. 9. Remove the backing from a piece of adhesive tape and adhere the tape to the original sound insulation and/or back side of the trim panel. 10. Finish attaching the remain pieces of adhesive tape to the original sound insulation and/or back side of the trim panel. 11. Verify that the new sound insulation is installed correctly. 12. Install the interior door trim panel to the door. 13. Verify that the buzz-like sound is corrected. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7467 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-06 Date: 060505 Audio System - Door Area Buzzing Sound With Audio ON NUMBER: 23-018-06 GROUP: Body DATE: May 05, 2006 SUBJECT: Speaker Buzz OVERVIEW: This bulletin involves adding insulating tape to the inner door and door trim panel. MODELS: 2006 (DR/DH/D1) Ram Truck SYMPTOM/CONDITION: Customers may experience a buzzing sound coming from the door area when the radio is on. DIAGNOSIS: Operate the radio with the bass and treble in the center position. The volume should be at the # 20 position with music playing. If the condition is present, perform the Repair Procedure. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7468 REPAIR PROCEDURE: 1. Using the procedures outlined in Section 23 of the 2006 Ram Truck Service Information on TechCONNECT, remove the door trim panel on the door that has the condition. 2. Remove the speaker from the inner door panel but do not disconnect the speaker wires. 3. Operate the radio as described earlier while holding the speaker by the magnet in your hand, Listen from the side of the speaker for the buzzing sound. If the sound is coming from the speaker. The speaker requires replacing and the remainder of this procedure can be skipped. If the sound is not present, proceed to step 4. 4. Apply three 6 inch pieces of foam tape, p/n 04318028 to the area shown on the inner door panel sheet metal. (Fig. 1). 5. Install the water shield. 6. Install the speaker on to the inner door panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > Page 7469 7. Carefully pry map pocket on the lower door trim panel away from the support post on the door trim panel as shown (Fig. 2). 8. Apply a 1 inch by 1 inch square of felt tape, p/n 05019055AA to the support post to isolate the support post from the map pocket panel (Fig. 2). 9. Install the door trim panel. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures Front Door Panel: Procedures REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 7472 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 7473 Front Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 7474 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Waterdam WATERDAM REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 7475 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the B-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 N.m (21 ft.lbs.). 4. Verify correct door and latch position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 7479 Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the B-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the B-pillar and remove the striker. INSTALLATION 1. Position the door latch striker (1) onto the B-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the B-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 N.m (21 ft.lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7484 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer A-PILLAR WEATHERSTRIP RETAINER REMOVAL 1. Remove the drip rail weatherstrip retainer (1). 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7485 Front Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7486 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7487 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7488 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7489 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7490 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7491 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7492 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer DRIP RAIL WEATHERSTRIP RETAINER REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7498 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7499 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7500 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7501 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7502 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7503 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 7504 2. Install the door trim panel (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel. 4. Remove the 2 mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Rotate the assembly and remove the 3 screws (1) that attach the motor to the regulator. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair > Page 7508 1. Install the power motor to the regulator with the 3 screws (1). 2. Connect the electrical connector to the power motor. 3. Install the 2 mounting bolts (1). 4. Install the rear cab back panel. 5. Install the rear seats. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures Manual REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7513 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Power REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7514 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7515 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7516 Front Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7517 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7518 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 7519 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove the front glass run channel, Refer to Window Track. 2. Disconnect the actuator rod (1) from the exterior door handle (2). 3. Remove the two nuts (3) that secure the exterior door handle to the door and remove the handle. INSTALLATION 1. Position the exterior handle (2) into the door. 2. Install the two nuts (3) that secure the exterior handle to the door. Tighten the nuts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (1) to the exterior handle. 4. Install the front glass run channel, Refer to Window Track. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair INTERIOR HANDLE ACTUATOR REMOVAL 1. Remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (2) from interior door handle actuator (3). 3. Remove the two bolts (1) that secure the interior door handle actuator to the door and remove the actuator. INSTALLATION 1. Position the interior door handle actuator (3) onto the door. 2. Install the two bolts (1) that secure the interior door handle actuator to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the actuator rod (2) to the interior door handle actuator. 4. Reposition the waterdam and install the door trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7536 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7537 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7543 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 7544 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7545 Rear Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7546 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7547 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7548 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 7549 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7550 Rear Door Hinge: Service and Repair HINGE REMOVAL NOTE: - It is not necessary to remove the door to replace the hinges if they are replaced one at a time. - The epoxy coated washers should not be removed from the hinge. If the washers are removed the door may have to be re-adjusted. 1. Open the front door UPPER HINGE 1. Using a grease pencil or equivalent, mark the position of the hinge (2) on the door and b-pillar. 2. Remove the nut (1) and bolt (9) attaching the hinge (2) to the door. 3. Remove the three bolts (6) attaching the hinge to the b-pillar and remove the hinge. LOWER HINGE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7551 1. Using a grease pencil or equivalent, mark the position of the hinge on the door and b-pillar. 2. Remove the lower b-pillar trim. Refer to Trim Panel. 3. Remove the nut (1) and bolt (9) attaching the hinge to the door. 4. Remove the two bolts (5) attaching the hinge to the b-pillar. 5. From the inside of the vehicle remove the remaining bolt (4) attaching the hinge to the b-pillar and remove the hinge. INSTALLATION UPPER HINGE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7552 1. Install the hinge to door washers, if there were removed previously, nut (1) and bolt (9) and tighten to 28 N.m (21 ft.lbs.). 2. Tighten the upper hinge bolt (2) to 28 N.m (21 ft.lbs.). 3. Tighten the upper hinge bolt (1) to 28 N.m (21 ft.lbs.). 4. Tighten the upper hinge bolt (3) to 28 N.m (21 ft.lbs.). 5. Adjust the door if needed. LOWER HINGE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Page 7553 1. Install the hinge and install the b-pillar bolts. 2. Tighten the upper hinge bolt (2) to 28 N.m (21 ft.lbs.). 3. Tighten the upper hinge bolt (1) to 28 N.m (21 ft.lbs.). 4. Tighten the upper hinge bolt (3) to 28 N.m (21 ft.lbs.). 5. Install the hinge to door washers, if there were removed previously, nut and bolt and tighten to 28 N.m (21 ft.lbs.). 6. Adjust the door if needed. 7. Install the lower b-pillar trim. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams Rear Door Latch: Diagrams Latch-Door - Left Rear (Base) Latch-Door - Left Rear (Power Locks) Latch-Door - Right Rear (Base) Latch-Door - Right Rear (Power Locks) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7557 Rear Door Latch: Adjustments ADJUSTMENTS 1. Locate the access hole in the door to adjust the door latch (1) and remove the mylar tape (2). 2. Loosen the adjustment screw (3). 3. Operate the door handles several times to reduce any possible linkage binding and tighten the adjustment screw to 3 N.m (30 in.lbs.). 4. Operate the door handles again to verify proper operation and reinstall the mylar tape. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7558 Rear Door Latch: Service and Repair LATCH REMOVAL 1. Raise the window to the full up position and remove the door trim panel. 2. Position the waterdam out of the way and disconnect the actuator rod (1) from the interior door handle actuator (2) and the door latch (5) and remove the rod. 3. Disconnect the two actuator rods (3 and 4) from the door latch. 4. Disconnect the door wire harness connector (2) from the door latch (3). 5. Remove the three bolts (4) that secure the door latch to the door (1) and remove the latch. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Diagrams > Page 7559 1. Position the door latch (3) into the door (1). 2. Install the three bolts (4) that secure the door latch to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 3. Connect the door wire harness connector (2) to the door latch. 4. Connect the two actuator rods (3 and 4) to the door latch (5) 5. Connect the actuator rod (1) to the door latch and the interior door handle actuator (2). 6. Reposition the waterdam to the door and install the door trim panel. 7. If necessary, adjust the latch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures Rear Door Panel: Procedures REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator (1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank using a window crank removal tool (1). 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7564 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7565 Rear Door Panel: Removal and Replacement Trim Panel TRIM PANEL REMOVAL 1. Remove the screw (3) that secures the interior door handle (2) to the interior door handle actuator(1). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (2) using a window crank removal tool (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7566 4. Remove the screw (4) that secures the door trim panel (5) to the screw insert located in the center of the door (1). CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 5. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (3) from the door. 6. If equipped, disconnect the door wire harness (2) from the power door switch assembly and remove the door trim panel. INSTALLATION 1. If equipped, connect the door wire harness (2) to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (5) and align the molded plastic retaining clips (3) to the door (1). 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the screw (4) that secures the door trim panel to the screw insert located in the center of the door. 5. if equipped, install the manual window crank. Waterdam WATERDAM REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Procedures > Page 7567 1. Remove the interior door handle actuator. 2. Remove the speaker. CAUTION: Do not allow the waterdam adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. 3. Carefully remove the waterdam (1) from around the perimeter of the rear door (2). 4. Separate the waterdam from the interior handle actuator rod and the door wire harness (if equipped) and remove the waterdam. INSTALLATION CAUTION: Do not allow the waterdam or adhesive to become contaminated with dirt or other foreign substances. If the waterdam becomes contaminated or damaged, replace it. NOTE: Be sure that the waterdam is fully sealed around the perimeter of the door. 1. Position the interior handle actuator rod and the wire harness (if equipped) through the holes in the waterdam (1) and install the waterdam to the door (2). 2. Install the speaker. 3. Install the interior door handle actuator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments ADJUSTMENTS 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2) to aid in adjustment. 2. Loosen the two bolts (3) that secure the door latch striker to the C-pillar. 3. To adjust the rear gap and flush measurement, change the position of the door latch striker and then tighten the two bolts to 28 N.m (21 ft.lbs.). 4. Verify correct door and latch position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Page 7571 Rear Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Using a grease pencil or equivalent, mark the location of the door latch striker (1) on the C-pillar (2). 2. Remove the two bolts (3) that secure the door latch striker to the C-pillar and remove the striker. INSTALLATION 1. Position the door latch striker (1) onto the C-pillar (2) and loosely install the two bolts (3). 2. Align the door latch striker to the C-pillar using the reference marks made during the removal procedure and tighten the bolts to 28 N.m (21 ft.lbs.). 3. If necessary, adjust the door latch striker. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7576 Rear Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7577 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7578 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7579 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7580 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7581 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 7582 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7588 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7589 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7590 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7591 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7592 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 7593 2. Install the door trim panel (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures Manual REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7598 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Power REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7599 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7600 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7601 Rear Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7602 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7603 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 7604 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding . Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair Fuel Door: Service and Repair FUEL FILL DOOR REMOVAL 1. Open the fuel filler door (1). 2. Remove the two bolts (2) that secure the fuel filler door to the cargo box and remove the door. INSTALLATION 1. Position and align the fuel filler door (1) to the cargo box. 2. Install the two bolts (2) that secure the fuel filler door to the cargo box. Tighten the bolts to 9 N.m (80 in.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE NOTE: It is not necessary to remove the hood to replace the hood hinges. Hood hinges can be replaced one at a time. REMOVAL 1. Remove the cowl grille. 2. Using a grease pencil or equivalent, mark the position of the hood hinge (3) on the hood for the hinge being serviced. 3. Support the hood and disconnect the support cylinder from the hood, Refer to Hood Shock / Support. 4. Remove the two nuts that secure the hood to the hood hinge. 5. Remove the bolt (2) that secures the front fender (1) to the hood hinge. 6. Remove the wheelhouse splash shield. 7. Remove the bolts (3) that secure the hood hinge (2) to the fender rail (1). 8. Slide the hood hinge forward and remove the hinge. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 7612 1. Position the hood hinge (2) onto the fender rail (1) and slide it rearward to its installed location. 2. Install the bolts (3) that secure the hood hinge to the fender rail. Tighten the bolts to 20 N.m (15 ft.lbs.). 3. Install the bolt (2) that secures the front fender (1) to the hood hinge (3). Tighten the bolt to 12.5 N.m (9 ft.lbs.). 4. Loosely install the two nuts that secure the hood to the hood hinge. 5. Align the hood to the hood hinge using the reference marks made during the Removal procedure and tighten the nuts to 23 N.m (17 ft.lbs.). 6. Install the support cylinder. 7. If required, adjust the hood to the correct position. 8. Install the wheelhouse splash shield. 9. Install the cowl grille. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch Hood Latch: Service and Repair Latch LATCH REMOVAL 1. Using a grease pencil or equivalent, mark the position of the hood latch (1) on the upper radiator crossmember. 2. Remove the two bolts (3) that secure the hood latch to the upper radiator crossmember. 3. Disconnect the hood latch cable (2) from the hood latch and remove the latch. INSTALLATION 1. Connect the hood latch cable (2) to the hood latch (1). 2. Position the hood latch to the upper radiator cross-member and loosely install the two bolts (3) that secure the latch to the crossmember. 3. Align the hood latch to the upper radiator cross-member using the reference marks made during the Removal procedure and tighten the bolts to 11 N.m (8 ft.lbs.). 4. If required, adjust the hood to the correct position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Latch > Page 7617 Hood Latch: Service and Repair Latch Striker/Secondary Catch LATCH STRIKER/SECONDARY CATCH REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 N.m (8 ft.lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE/HANDLE ASSEMBLY REMOVAL 1. Remove the hood latch. 2. Remove the battery tray from the left side of the engine compartment. 3. Remove the three hood release cable retainers from the upper radiator crossmember and the left fender rail. 4. From inside the vehicle, remove the two bolts (1) that secure the hood release handle (2) to the instrument panel bracket (3). 5. Remove the grommet (4) from the cowl panel and remove the hood release cable and handle assembly. INSTALLATION 1. Route the hood release cable through the cowl panel and install the grommet (4). 2. Position the hood release handle (2) onto the instrument panel bracket (3). 3. Install the two bolts (1) that secure the hood release handle to the instrument panel bracket. Tighten the bolts to 9 N.m (80 in.lbs.). 4. Route the hood release cable along the left fender rail and the upper radiator crossmember and install the three hood release cable retainers. 5. Install the battery tray to the left side of the engine compartment. 6. Install the hood latch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair SUPPORT CYLINDER REMOVAL NOTE: The hood support cylinders can be replaced one at a time. 1. Open and support the hood. CAUTION: Do not pull on the hood support cylinders at the middle of the support cylinder during removal. Failure to follow this caution can result in damage to the hood support cylinders. 2. Using a small flat bladed tool, or equivalent (3), release the retaining clip (2) at each end of the support cylinder while carefully pulling the ball socket (1) away from the ball stud (4). NOTE: Lift the clips (1) only enough to release the ball studs (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 7624 3. Disconnect the hood support cylinder (5) from the hood (1) and the fender rail (3). 4. If required, remove the upper ball stud (2) from hood and the lower ball stud (4) from the fender rail. INSTALLATION 1. If removed, install the upper ball stud (2) onto the hood (1) and the lower ball stud (4) onto the fender rail (3). Install the ball studs securely. CAUTION: Do not push on the hood support cylinders at the middle of the support cylinder during installation. Failure to follow this caution can result in damage to the hood support cylinders. NOTE: Install the hood support cylinders with the cylinder end connected to the hood as shown. - If required, only release each retaining clip enough to install the ball socket onto the ball stud. 2. Install the hood support cylinder (5) over the upper and lower ball studs and fully engage the retaining clips. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Service and Repair Hood Striker: Service and Repair LATCH STRIKER/SECONDARY CATCH REMOVAL 1. Disconnect the release handle (4) from the secondary hood latch and striker assembly (2) and remove the handle from the grille frame (5). 2. Remove the two bolts (3) that secure the secondary hood latch and striker assembly to the hood and remove the assembly. INSTALLATION 1. Position the secondary hood latch and striker assembly (2) to the hood. 2. Install the two bolts (3) that secure the secondary hood latch and striker assembly to the hood. Tighten the bolts to 11 N.m (8 ft.lbs.). 3. Install the release handle (4) through the grille frame (5) and connect it to the secondary hood latch. 4. If required, adjust the hood to the correct position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair Body Emblem: Service and Repair EXTERIOR NAME PLATES NOTE: Mega Cab model shown in the illustration. Exterior name plates and decals for all other cab models are similar. Exterior name plate and decal usage vary by model. REMOVAL Name Plates 1. As a guide for installation, apply a length of masking tape on the body (1), parallel to the top edge and, to one end of the name plate or decal (2) being removed. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the name plate or decal with a heat lamp or heat gun. NOTE: The exterior name plates are attached to the body with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the name plate or decal from the body panel, as necessary. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Page 7632 Name Plates 1. Thoroughly clean all residue from the name plate or decal attachment areas of the body (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating name plates, decals or body panels. Failure to follow this caution may result in damage to the name plates, decals and/or the vehicle paint finish. NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the name plate or decal and body panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of name plate or decal (2) and position the name plate or decal onto the body using the previously installed guide tape. NOTE: To ensure proper name plate or decal adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each name plate or decal. 4. Install the name plate or decal onto the body. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair BODY SIDE MOLDINGS NOTE: Quad Cab model shown in the illustration. Body side moldings for Regular cab models are similar. REMOVAL 1. As a guide for installation, apply a length of masking tape on the rocker panels (1), parallel to the top edge and, to one end of the body side molding (2 and 3) being removed CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. 2. If the temperature is below 21 degrees C (70 degrees F), warm the body side moldings with a heat lamp or heat gun. NOTE: The body side moldings are attached to the cab with adhesive tape. 3. Using a trim stick C-4755 or equivalent, carefully remove the moldings from the rocker panels, as necessary. INSTALLATION 1. Thoroughly clean all residue from the molding attachment areas of the rocker panels (1). 2. Wipe the attachment areas with a clean, lint-free cloth, moistened with a 50% solution of water and alcohol and then wipe dry the areas immediately with a dry, lint-free cloth. CAUTION: Do not exceed 52 degrees C (120 degrees F) when heating the moldings or rocker panels. Failure to follow this caution may result in damage to the moldings and/or the vehicle paint finish. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Page 7639 NOTE: If ambient temperatures are below 21 degrees C (70 degrees F), warm the body side molding and rocker panel with a heat lamp or gun to assure proper adhesion. 3. Remove the protective covering from the back of the body side molding (2 and 3) and position the molding onto the rocker panel using the previously installed guide tape. NOTE: To ensure proper molding adhesion, apply consistent and uniform pressure of approximately 40 p.s.i. over the entire surface of each body side molding. 4. Install the body side molding onto the rocker panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Open the hood and disengage any wiring or component retaining clips from the front splash shield (4) (depending on application and shield being serviced). 2. Raise and support the vehicle. 3. Remove the eight screws (3) that secure the front splash shield to the fender rail (1) and the front fender (2). 4. Disconnect the front splash shield from the support bracket located on the front bumper and remove the splash shield. INSTALLATION 1. Install the front edge of the front splash shield (4) into the support bracket located on the front bumper. 2. Position the front splash shield onto the fender rail (1) and the front fender (2). 3. Install the eight screws (3) that secure the front splash shield to the fender rail and the front fender. Tighten the screws to 5 N.m (44 in.lbs.). 4. Lower the vehicle and engage any wiring or component retaining clips to the front splash shield (depending on application and shield being serviced). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1. Raise and support the vehicle. 2. Remove the three screws (2) that secure the rear splash shield (3) to the cargo box (1) and remove the splash shield. INSTALLATION 1. Position the rear splash shield (3) onto the cargo box (1). 2. Install the three screws (2) that secure the rear splash shield to the cargo box. Tighten the screws to 5 N.m (44 in.lbs.). 3. Lower the vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair Body / Frame Mount Bushing: Service and Repair BODY ISOLATORS NOTE: Quad Cab model shown in the illustration. Body isolators for Regular cab models are similar. REMOVAL 1. Loosen all cab to frame mounting bolts (5) (six Regular cab, eight Quad Cab). 2. Remove the mounting bolts and rebound cushions (3) as necessary. NOTE: If servicing the rear isolators (2), remove the reinforcement plates (6) and the washers (4). 3. Using a floor jack and wooden block under the cab sill (1), lift the body to gain access to the isolators and remove the isolators as necessary. INSTALLATION 1. Position the isolators (2) under the cab as necessary. CAUTION: If servicing the rear isolators, install the reinforcement plates (6) and the washers (4). 2. Lower the cab onto the isolators and install the mounting bolts (5) and rebound cushions (3) as necessary (six Regular cab, eight Quad Cab). 3. Tighten the mounting bolts to 81 N.m (60 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair Front Cross-Member: Service and Repair TRANSMISSION CROSSMEMBER REMOVAL 1. Raise and support the vehicle. 2. Remove the transfer case skid plate (3-if equipped). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 7657 3. Support the transmission (1) with a transmission jack (2) or suitable lifting device. 4. 2WD Vehicles-Remove the transmission mount nuts (3). 5. Remove the bolts and remove the crossmember (2). 6. 4WD Vehicles-Remove the transmission mount nuts (5). 7. Remove the bolts (3) and remove the crossmember (4). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 7658 1. On Light Duty Vehicles, install the crossmember (2) and the bolts (4). Tighten the bolts to 102 N.m (75 ft.lbs.). 2. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 3. On Heavy Duty Vehicles, install the crossmember (4) and the bolts (3). Tighten the bolts to 115 N.m (85 ft.lbs.). 4. Install the transmission mount nuts and tighten to 54 N.m (40 ft.lbs.). 5. Remove the transmission support (2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Page 7659 6. Install the transfer case skid plate (3-if equipped). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate Skid Plate: Service and Repair Front Skid Plate FRONT SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts (3). 3. Slide skid plate (2) back off of the crossmember (1) and remove. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 7664 1. Snap the rear tabs over the front crossmember (1) and install the skid plate (2). 2. Install the bolts (3) and tighten to 34 N.m (25 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 7665 Skid Plate: Service and Repair Transfer Case Skid Plate TRANSFER CASE SKID PLATE REMOVAL 1. Raise and support the vehicle. 2. Support the skid plate (3) and remove the bolts (4). 3. Remove the skid plate (3). 4. Support the skid plate crossmember (2) and remove the bolts (1). 5. Remove the skid plate crossmember (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Front Skid Plate > Page 7666 1. Install the skid plate crossmember (2) and bolts (1). 2. Tighten the bolts (1) to 34 N.m (25 ft.lbs.). 3. Install the skid plate (3) and bolts (4). 4. Tighten the bolts (4) to 34 N.m (25 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair Trailer Hitch: Service and Repair TRAILER HITCH REMOVAL 1. Remove the rear bumper. 2. On Light Duty Vehicles, remove the hitch bolts (7) 3. On Heavy Duty Vehicles, remove the hitch bolts (8) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7670 4. Disconnect all wire harness support push pins. 5. Remove the rear two cargo box bolts (3) and loosen the remaining bolts. 6. Using a suitable lifting device, lift and support the rear of the cargo box and remove the hitch. INSTALLATION 1. On Light Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 2. Install the hitch bolts (7) and tighten to 170 N.m (125 ft.lbs.). 3. Connect all wire harness support push pins. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Page 7671 4. On Heavy Duty Vehicles, install the hitch (5) onto the frame rails and make sure the locators (1 and 2) on the inside of the hitch brackets are engaged with the holes in the top of the frame rails properly. 5. Install the hitch bolts (8) and tighten to 170 N.m (125 ft.lbs.). 6. Connect all wire harness support push pins. 7. Lower the cargo box and install the rear bolts (3). 8. Install the rear bumper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille Grille: Service and Repair Grille GRILLE REMOVAL 1. Open the hood (2) and remove the six screws (5) that secure the grille (3) to the grille frame (4). 2. Remove the six nuts (1) that secure the grille to the hood and remove the grille. 3. If required, remove the grille frame from the hood. INSTALLATION 1. If removed, install the grille frame (4). 2. Position and align the grille (3) onto the hood (2) 3. Install the six nuts (1) that secure the grille to the hood. Tighten the nuts to 5 N.m (44 in.lbs.). 4. Install the six screws (5) that secure the grille to the grille frame. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille > Page 7676 Grille: Service and Repair Grille Frame GRILLE FRAME REMOVAL 1. Remove the grille. 2. Remove the six screws (3) that secure the grille frame (2) to the hood (1) and remove the frame. INSTALLATION 1. Position the grille frame (2) onto the hood (1). 2. Install the six screws (3) that secure the grille frame to the hood. Tighten the screws to 5 N.m (44 in.lbs.). 3. Install the grille. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair Arm Rest: Service and Repair CENTER ARMREST/SEAT BACK REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Remove the center seat. 3. Disconnect the storage bin/cushion cover j-straps and position aside. 4. Remove and discard the hinge bolts (2) and separate the seat back from the storage bin/cushion (1). INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Install the seat back onto the storage bin/cushion (1) and install new hinge bolts (2). 3. Tighten the hinge to storage bin/cushion bolts (2) to 25 N.m (18 ft.lbs.). 4. Connect the storage bin/cushion cover j-straps. 5. Install the center seat. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair Carpet: Service and Repair CARPETS AND FLOOR MATS NOTE: Carpet for Quad Cab model shown. Regular cab similar. REMOVAL 1. Remove the front seats. 2. If equipped, remove the floor console. 3. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear trim panel (4). 4. On Quad Cab models, remove the rear seats (1). 5. On Quad Cab models, remove the rear cup holder (2) using a trim stick C-4755 or equivalent. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7684 6. Remove the lower B-pillar trim panels, Refer to Trim Panel. 7. On Quad Cab models, remove the bolt that secures the lower seat belt anchor to the floor panel near the B-pillars. 8. Remove the retaining screw (1) that secures the jack assembly (2) to the floor panel (3) and remove the jack assembly. 9. Remove the two bolts (4) that secure the jack assembly to the floor panel. 10. For trucks equipped with a scissor type jack, remove the bolts (1) and remove the jack (2). 11. Remove the screws and remove the load floor storage strap snaps (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7685 12. On Quad Cab models, remove the eleven pushpin fasteners (1) that secure the rear of the carpet (2) to the floor panel (3). 13. Remove the carpet from the vehicle. INSTALLATION 1. Position the carpet (2) into the vehicle. 2. On Quad Cab models, install the eleven push-pin fasteners (1) that secure the carpet to the floor panel (3). 3. Install the load floor storage snaps and screws (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7686 4. On trucks equipped with a scissor jack, install the jack and install the bolts (1). 5. Install the two bolts (4) that secure the jack assembly (2) to the floor panel (3). 6. Position the jack assembly onto the two bolts and install the retaining screw (1). Tighten the screw securely. 7. On Quad Cab models, install the bolt that secures the lower seat belt anchors the floor panel near the B-pillars. Tighten the bolt to 40 N.m (30 ft.lbs.). 8. Install the lower B-pillar trim panels. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Page 7687 9. On Quad Cab models, install the rear seat (1). 10. On Quad Cab models, install the rear cup holder (2). 11. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 N.m (55 in.lbs.). 12. If equipped, install the floor console. 13. Install the front seats. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations Headliner Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7691 Console: Service and Repair FLOOR CONSOLE REMOVAL Mini Floor Console 1. If equipped, remove the 4WD gear shift boot. 2. If equipped with a manual transmission, remove the transmission gear shift lever extension. 3. Remove the console inserts, if equipped. 4. Remove the bolts (2) that secure the rear console (1) to the floor panel. 5. Lift up the rear of the floor console to clear the gear shift lever, if equipped. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7692 6. Remove the bolts (2) and separate the front console (3) from the floor. 7. Separate the front clips (1) and remove the mini console. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. 2. Using a trim stick C-4755 or equivalent, separate the seven front console bezel clips (2), lift up the back of the bezel (1) and remove. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7693 3. Remove the bolts (1) and lift the rear of the base up to release the front guide pins (5). 4. Remove the front base (2). NOTE: Do not reuse the seat fasteners, always replace with new ones. 5. Remove and discard the front bolts (4). 6. Position the seats forward, remove the rear bolts (2) and discard. 7. Disconnect the 12 v power supply electrical connector (3-if equipped). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7694 8. Fold the seat backs forward and roll the seat assembly (1) back in the vehicle. 9. Remove the nuts (2) attaching the center seat console (1) to the drivers seat and the passenger seat and discard. 10. Remove the nuts (4) attaching the center console (2) to the drivers seat (3) and the passenger seat in the rear of the seat and discard. 11. Disconnect the electrical connector (1-if equipped). 12. Roll the seat assembly forward and remove the center seat console. INSTALLATION Mini Floor Console Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7695 1. Position the console and seat the front clips (1) fully. 2. Install the bolts (2). 3. Install the bolts (2) that secure the rear console (1) to the floor panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7696 4. Install the inserts. 5. Install the gear shift lever extension. 6. Install the 4WD gear shift boot. Full Floor Console 1. Before proceeding with the following repair procedure, review all warnings and cautions. Refer to Seats / Service Precautions. NOTE: Do not reuse the seat fasteners, always replace with new ones. 2. Position the center seat console onto the front seat assembly and roll the seat assembly back in the vehicle. 3. Install new nuts (4) attaching the center console to the drivers (3) and passenger seat. 4. Connect the electrical connector (1-if equipped). 5. Tighten the nuts (4) to 25 N.m (18 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Locations > Page 7697 6. Install new nuts (2) attaching the center console (1) to the drivers and passenger seat. 7. Tighten the nuts to 25 N.m (18 ft.lbs.). 8. Connect the electrical connector (3 and 5-if equipped). 9. Roll the seat assembly forward and install new rear bolts (2). 10. Connect the 12 v power supply electrical connector (3-if equipped). 11. Tighten the rear bolts to 40 N.m (30 ft.lbs.). 12. Fold the seat backs up and slide the seats to the rear. 13. Install new front bolts (4) and tighten to 28 N.m (21 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7703 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7704 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair REMOVAL 1. Remove the bezel (2). 2. Remove the screws (2) and remove the cup holder (1). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair > Page 7708 1. Position the cup holder (2) onto the clips (1) and seat fully. 2. Install the screws (2). 3. Position the bezel and seat the clips fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Glove Compartment: Service and Repair Glove Box REMOVAL 1. Open the glove box (1). 2. Release the two glove box stops (2) and lower the glove box downward past the stops. 3. Disengage the glove box hinges from the instrument panel and remove the glove box. INSTALLATION 1. Engage the hinges of the glove box (1) to the instrument panel. 2. Press downward on the back edge of the glove box bin and raise the glove box past the two stops (2). 3. Close the glove box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 7713 Glove Compartment: Service and Repair Glove Box Latch Replacement REMOVAL 1. Remove the glove box and place it on a workbench. 2. Remove the 15 screws (1) that secure the glove box bin (2) and the inner glove box door panel (3) to the outer glove box door panel (4). 3. Remove the glove box bin and the inner glove box door panel from the outer glove box door panel. 4. Remove the two screws (1) that secure the glove box latch (2) to the outer glove box door panel (3) and remove the latch. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 7714 1. Position the glove box latch (2) into the outer glove box door panel (3). 2. Install the two screws (1) that secure the glove box latch to the outer glove box door panel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Position the inner glove box door panel (3) and the glove box bin (2) onto the outer glove box door panel (4). 4. Install the fifteen screws (1) that secure the inner glove box door panel and the glove box bin to the outer glove box door panel. Tighten the screws to 2 N.m (17 in. lbs.). 5. Install the glove box. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures Headliner: Procedures REMOVAL 1. Remove the headliner. 2. Remove the 12 nuts (1) and roll the trim ring off the headliner off the retaining flanges (2). INSTALLATION 1. Position trim ring support flanges (2) over the headliner and seat the trim ring fully. 2. Install the 12 nuts (1) onto the support studs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 7719 Headliner: Removal and Replacement HEADLINER NOTE: Headliner for Quad Cab model shown. Regular cab similar. REMOVAL 1. Remove the A-pillar trim panels, Refer to Trim Panel. 2. Remove the upper B-pillar trim panels, Refer to Trim Panel. 3. On Quad Cab models, remove the upper C-pillar trim panels, Refer to Trim Panel. 4. Disconnect the wire harness connector (1) located at the left A-pillar from the headliner wire harness (2). 5. Disconnect the headliner wire harness connector (3) from the inside rear view mirror. 6. Remove the overhead console. 7. Remove the sun visors (4). 8. Remove the sun visor supports (5). 9. Remove the dome lamp (6). 10. Remove the two coat hooks (7). 11. Lower the rear of the headliner (9) downward from the roof panel (10) and disconnect the headliner wire harness connector (8) from the center high mounted stop lamp. 12. Lower the front of the headliner downward and remove the headliner through the passenger door opening. INSTALLATION 1. Position the headliner (9) into the vehicle through the passenger door opening. 2. Connect the headliner wire harness connector (8) to the center high mounted stop lamp. 3. Raise the rear of the headliner upward and install the two coat hooks (7). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Procedures > Page 7720 4. Raise the front of the headliner upward and install the sun visor supports (5). 5. Install the sun visors (4). 6. Install the dome lamp (6). 7. Install the overhead console. 8. Connect the headliner wire harness connector (3) to the inside rear view mirror. 9. Connect the headliner wire harness (2) to the wire harness connector (1) located at the left A-pillar. 10. On Quad Cab models, install the upper C-pillar trim panel. 11. Install the upper B-pillar trim panels. 12. Install the upper A-pillar trim panels. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor SUN VISOR REMOVAL 1. Remove the three screws (1) that secure each sun visor (2) to the roof panel and remove the visor from the headliner (3). 2. If equipped, disconnect the wire harness connector for the illuminated vanity mirror (4). INSTALLATION 1. If equipped, connect the wire harness connector for the illuminated vanity mirror (4). 2. Position the sun visor (2) onto the headliner (3). 3. Install the three screws (1) that secure each sun visor to the roof panel. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 7725 Sun Visor: Service and Repair Sun Visor Support SUN VISOR SUPPORT REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the release clip (3) as shown and remove the sun visor support (1) from the headliner (2) INSTALLATION 1. Position the sun visor support (1) through the headliner (2) and fully seat the base of the support to the roof panel. 2. Engage the release clip (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures Trim Panel: Procedures HEAT STAKING 1. Remove trim panel. 2. Bend or move the trim panel components at the heat staked joints. Observe the heat staked locations and/or component seams for looseness. 3. Heat stake the components. a. If the heat staked or component seam location is loose, hold the two components tightly together and using a soldering gun with a flat tip, melt the material securing the components together. Do not over heat the affected area, damage to the exterior of the trim panel may occur. b. If the heat staked material is broken or missing, use a hot glue gun to apply new material to the area to be repaired. The panels that are being heat staked must be held together while the applying the glue. Once the new material is in place, it may be necessary to use a soldering gun to melt the newly applied material. Do not over heat the affected area, damage to the exterior of the trim panel may occur. 4. Allow the repaired area to cool and verify the repair. 5. Install trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7730 Trim Panel: Removal and Replacement Cowl Trim COWL TRIM REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the cowl trim panel (1) from the retainer clips (2) in the door sill (3). 2. Pull the cowl trim panel rearward and remove it from the vehicle. INSTALLATION 1. Position the cowl trim panel (1) onto the door sill (3). 2. Push the cowl trim panel forward and then engage the retaining tabs that secure the sill trim panel to the rear door sill. Front Door Trim Panel TRIM PANEL REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7731 1. Remove the screw (1) that secures the interior door handle (2) to the interior door handle actuator (3). 2. Remove the interior door handle from the interior door handle actuator. 3. If equipped, remove the manual window crank (1) using a window crank removal tool (2). 4. Remove the two screws (2) that secure the door trim panel (3) to the two screw inserts (1). 5. Remove the two screws (4) that secure the door trim panel to the bottom of the door. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not pull the door trim panel directly off of the door or damage to the trim panel and/or the power switch assembly will occur. 6. Lift the door trim panel straight upward to disconnect the molded plastic retaining clips (5) from the door. 7. If equipped, disconnect the door wire harness from the power door switch assembly and remove the door trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7732 INSTALLATION 1. If equipped, connect the door wire harness to the power door switch assembly. CAUTION: The door trim panel is attached to the door by molded plastic retaining clips that are integral to the door trim panel. Do not force the door trim panel onto the door or damage to the trim panel and/or the power switch assembly will occur. 2. Position the door trim panel (3) and align the molded plastic retaining clips (5) to the door. 3. Push the door trim panel straight downward until all of the retaining clips are fully engaged to the door. 4. Install the two screws (2) that secure the door trim panel to the two screw inserts (1). 5. Install the two screws (4) that secure the door trim panel to the bottom of the door. 6. if equipped, install the manual window crank. 7. Position the interior door handle (2) onto the interior door handle actuator (3). 8. Install the screw (1) that secures the interior door handle to the interior door handle actuator. Tighten the screw securely. Load Floor LOAD FLOOR REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7733 1. Move the rear seat cushion (1) to the up position. 2. Remove the two nuts (2) that secure the rear of the load floor (3) to the floor panel. 3. Move the load floor (2) to the up position. 4. Remove the two bolts (3) that secure the load floor to the floor panel (1) and remove the load floor. 5. If required, remove the support cylinder (4), Refer to Utility Storage Compartment. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7734 1. If removed, install the load floor support cylinder (4). 2. Position the load floor (2) into the vehicle and install the two bolts (3) that secure it to the floor panel (1). Tighten the bolts to 40 N.m (30 ft.lbs.). 3. Move the load floor (3) to the down position and install the two nuts (2) that secure the load floor to the floor panel. Tighten the nuts to 25 N.m (18 ft.lbs.). 4. Move the rear seat cushion (1) to the down position. A-Pillar Trim A-PILLAR TRIM/GRAB HANDLE REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7735 1. Using a small flat-bladed tool, carefully open the two fastener covers (3) located in the a-pillar trim panel (2). 2. Remove the two bolts (4) that secure the a-pillar trim panel to the a-pillar (1) and remove the trim panel. INSTALLATION 1. Position the locating tab of the A-pillar trim panel (2) into the slot located in the top of the instrument panel. 2. Install the A-pillar trim panel onto the A-pillar (1) and install the two bolts (4). Tighten the bolts to 6 N.m (55 in.lbs.). 3. Close the two fastener covers (3) located in the A-pillar trim panel. B-Pillar Grab Handle B-PILLAR GRAB HANDLE REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7736 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. INSTALLATION 1. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 N.m (55 in.lbs.). 2. Close the two fastener covers (2) located on the grab handle. B-Pillar Lower Trim B-PILLAR LOWER TRIM REMOVAL REGULAR CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7737 1. Remove the cowl trim panel, Refer to Trim Panel. 2. Remove the upper B-pillar trim panel, Refer to Trim Panel. 3. Remove the bolt (2) that secures the seat belt (1) to the bottom of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (3) to the B-pillar. 5. Remove the seat belt from the lower B-pillar trim panel through the slot provided and remove the trim panel. QUAD CAB 1. Remove the cowl trim panel, Refer to Trim Panel. 2. Remove the rear door sill trim cover, Refer to Trim Panel. 3. Remove the upper B-pillar trim panel, Refer to Trim Panel. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower B-pillar trim panel (1) to the B-pillar (2). 5. Remove the seat belt (3) from the lower B-pillar trim panel through the slot provided and remove the trim panel. INSTALLATION REGULAR CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7738 1. Route the seat belt (1) through the slot in the lower B-pillar trim panel (3) and position the trim panel to the B-pillar (4). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt to the bottom of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the upper B-pillar trim panel. 5. Install the cowl trim panel. QUAD CAB 1. Route the seat belt (3) through the slot in the lower B-pillar trim panel (1) and position the trim panel to the B-pillar (2). 2. Engage the retaining tabs that secure the lower B-pillar trim panel to the B-pillar. 3. Install the upper B-pillar trim panel. 4. Install the rear door sill trim cove, Refer to Trim Panel. 5. Install the cowl trim panel. B-Pillar Upper Trim B-PILLAR UPPER TRIM REMOVAL REGULAR CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7739 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. QUAD CAB 1. Using a small flat-bladed tool, carefully open the two fastener covers (2) located on the grab handle (1). 2. Remove the two bolts (3) that secure the grab handle to the B-pillar and remove the grab handle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7740 3. Remove the cap (1) and the bolt (2) that secures the seat belt (3) to the top of the B-pillar (4) and position the seat belt out of the way. 4. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper B-pillar trim panel (5) to the B-pillar and remove the trim panel. INSTALLATION REGULAR CAB 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. QUAD CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7741 1. Position the upper B-pillar trim panel (5) to the B-pillar (4). 2. Engage the retaining tabs that secure the upper B-pillar trim panel to the B-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the B-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. 5. Install the grab handle (1) onto the B-pillar and install the two bolts (3). Tighten the bolts to 6 N.m (55 in.lbs.). 6. Close the two fastener covers (2) located on the grab handle. C-Pillar Lower Trim C-PILLAR LOWER TRIM REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7742 1. Remove the upper C-pillar trim panel, Refer to Trim Panel. 2. Remove the bolt (3) that secures the seat belt (2) to the bottom of the C-pillar (4) and position the seat belt out of the way. 3. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the lower C-pillar trim panel (1) to the C-pillar. 4. Remove the seat belt from the lower C-pillar trim panel through the slot provided and remove the trim panel. INSTALLATION 1. Route the seat belt (2) through the slot in the lower C-pillar trim panel (1) and position the trim panel to the C-pillar (4). 2. Engage the retaining tabs that secure the lower C-pillar trim panel to the C-pillar. 3. Install the bolt (3) that secures the seat belt to the bottom of the C-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the upper C-pillar trim panel. C-Pillar Upper Trim C-PILLAR UPPER TRIM REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7743 1. Remove the cap (1) and then the bolt (2) that secures the seat belt (3) to the top of the C-pillar (4) and position the seat belt out of the way. 2. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the upper C-pillar trim panel (5) to the C-pillar and remove the trim panel. INSTALLATION 1. Position the upper C-pillar trim panel (5) to the C-pillar (4). 2. Engage the retaining tabs that secure the upper C-pillar trim panel to the C-pillar. 3. Install the bolt (2) that secures the seat belt (3) to the top of the C-pillar. Tighten the bolt to 40 N.m (30 ft.lbs.). 4. Install the cap (1) onto the seat belt. Rear Cab Back Panel Trim REAR CAB BACK PANEL TRIM REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7744 1. If equipped, remove the three bolts (1) that secure the rear storage compartment (2) to the floor panel (3) and remove the storage compartment from the rear cab trim panel (4). 2. If equipped, using a trim stick C-4755 or equivalent, disengage the latch (4) for the utility hook cover (3) and open the cover to gain access to the screw (1) that secures the utility hook (2) to the rear cab back panel. 3. On Regular cab models, remove the lower B-pillar trim panels, Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7745 4. On Regular cab models, remove the utility hook (3) or the storage bin latch (4) (depending on application) from the rear cab trim panel (1) and remove the trim panel. 5. On Quad Cab models, remove the child seat tether straps from the rear cab back panel (2). 6. On Quad Cab models, remove the center seat belt trim bezel. 7. On Quad Cab models, remove the lower C-pillar trim panels, Refer to Trim Panel. 8. On Quad Cab models, remove the two push-pin fasteners (1 and 4) that secure the rear cab trim panel (3) to the rear cab back panel and remove the trim panel. INSTALLATION 1. On Quad Cab models, position the rear cab trim panel (3) onto the rear cab back panel (2) and install the two push-pin fasteners (1 and 4). 2. On Quad Cab models, install the lower C-pillar trim panels. 3. On Quad Cab models, install the center seat belt trim bezel. 4. On Quad Cab models, install the child seat tether straps. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7746 5. On Regular cab models, position the rear cab trim panel (1) onto the rear cab back panel (2) and install the utility hook (3) or the storage bin latch (4) (depending on application). 6. On Regular cab models, install the lower B-pillar trim panels. 7. If equipped, position the rear storage compartment (2) onto the rear cab trim panel (4) and install the three bolts (1). Tighten the bolts to 6 N.m (55 in.lbs.). Rear Door Scuff Plate REAR DOOR SILL TRIM COVER REMOVAL 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs of the sill trim panel (1) from the retainer clips in the rear door sill (2) and remove the trim panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Procedures > Page 7747 INSTALLATION 1. Position the sill trim panel (1) onto the rear door sill (2). 2. Engage the retaining tabs that secure the sill trim panel to the rear door sill. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Service and Repair Utility Storage Compartment Latch: Service and Repair UNDER SEAT STORAGE BIN LATCH REMOVAL 1. Open the under seat storage bin. 2. Remove the two screws and remove the latch assembly. INSTALLATION 1. Install the latch assembly and install the screws. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove the exterior door handle (1). 2. Remove the clip (3) that secures the lock cylinder lever (5) and the electric lock switch (4), if equipped, to the door lock cylinder (6). 3. Remove the screw (2) that secures the door lock cylinder to the exterior handle and remove the lock cylinder. INSTALLATION 1. Position the door lock cylinder (6) into the exterior door handle (1). 2. Install the screw (2) that secures the door lock cylinder to the exterior door handle. Tighten the screw securely. 3. Install the electric lock switch (4), if equipped, and the lock cylinder lever (5) to the door lock cylinder. 4. Install the clip (3) that secures the lock cylinder lever and the electric lock switch, if equipped, to the door lock cylinder. 5. Install the exterior door handle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7761 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7762 Module - Sentry Key Remote Entry Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, refer to Keyless Entry Transmitter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 7765 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS) and is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. The Sentry Key REmote Entry Module (SKREEM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC), the Powertrain Control Module (PCM)/Engine Control Module (ECM), the Gateway module (SRT10 vehicles with a hybrid bus only) and the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then listens for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends a valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 7766 SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator status messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator status message from the SKREEM tells the EMIC to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator status messages to the EMIC to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM detects an invalid key or if a key transponder- related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The SKREEM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Description and Operation > Page 7767 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry Keyless Entry Module: Service and Repair Module-Remote Keyless Entry REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7770 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7771 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7772 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7773 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair NOTE: Do not disturb the metal terminal near the batteries. Avoid touching the new batteries. Skin oils may cause battery deterioration. If batteries are touched, clean with rubbing alcohol. The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves near the key ring until the two halves unsnap. Be careful not to damage the rubber gasket when separating the case halves. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the two batteries with new 3V lithium 2016 cell. Install the batteries with the positive terminal up. Reference the "+ SIDE UP" on the inside of the bottom half of the transmitter case. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together until they snap back into place. Test transmitter operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation Power Door Lock Actuator: Description and Operation The lock mechanisms are actuated by a reversible electric motor mounted within each door. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. The door lock motors are controlled by the instrument cluster. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 7782 Power Door Lock Actuator: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7786 Right Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7787 Power Door Lock Switch: Diagrams Switch-Door Lock - Passenger Switch-Window/Door Lock - Driver C1 Switch-Window/Door Lock - Driver C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 7788 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock Power Door Lock Switch: Testing and Inspection Switch - Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock > Page 7791 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock > Page 7792 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Switch - Power Lock Power Door Lock Switch: Service and Repair Switch - Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Switch - Power Lock > Page 7795 Power Door Lock Switch: Service and Repair Switch - Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions Memory Positioning Systems: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7801 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7802 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7803 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7804 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7805 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7806 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7807 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7808 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7809 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7810 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7811 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7812 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7813 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7814 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7815 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7816 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7817 Memory Positioning Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7818 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7819 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 7820 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Page 7824 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching Paint: Customer Interest Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 7834 **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 7835 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 7836 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching Paint: All Technical Service Bulletins Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 7842 **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 7843 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-046-07 > Oct > 07 > Body - Horizontal Paint Surface Etching > Page 7844 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair Paint: All Technical Service Bulletins Body - Paint Etching Repair NUMBER: 23-003-06 GROUP: Body DATE: January 19, 2006 SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2006 (HB) Durango 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2006 (KJ) Liberty 2006 (LX) 300/Magnum 2006 (ND) Dakota 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to models built between April 10, 2005 and November 1, 2005 (MDH 0410XX to 1101Xx) and delivered to dealers after August 15, 2005. DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (pictures available in publication number 81-316-0507 - insect etching). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7849 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7850 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7851 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7852 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair Paint: All Technical Service Bulletins Body - Paint Etching Repair NUMBER: 23-003-06 GROUP: Body DATE: January 19, 2006 SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2006 (HB) Durango 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2006 (KJ) Liberty 2006 (LX) 300/Magnum 2006 (ND) Dakota 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to models built between April 10, 2005 and November 1, 2005 (MDH 0410XX to 1101Xx) and delivered to dealers after August 15, 2005. DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (pictures available in publication number 81-316-0507 - insect etching). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7858 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7859 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7860 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 23-003-06 > Jan > 06 > Body - Paint Etching Repair > Page 7861 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7862 Paint: By Symptom Technical Service Bulletin # 23-046-07 Date: 071030 Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7863 **2008** 2006 - (XK) Commander **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7864 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7865 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-003-06 Date: 060119 Body - Paint Etching Repair NUMBER: 23-003-06 GROUP: Body DATE: January 19, 2006 SUBJECT: Paint Repair - Etching Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7866 OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2006 (HB) Durango 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2006 (KJ) Liberty 2006 (LX) 300/Magnum 2006 (ND) Dakota 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to models built between April 10, 2005 and November 1, 2005 (MDH 0410XX to 1101Xx) and delivered to dealers after August 15, 2005. DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (pictures available in publication number 81-316-0507 - insect etching). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7867 SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7868 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7869 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-046-07 Date: 071030 Body - Horizontal Paint Surface Etching NUMBER: 23-046-07 GROUP: Body DATE: October 30, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-003-06, DATED JANUARY 19, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL YEARS AND MODELS. SUBJECT: Paint Repair - Etching OVERVIEW: This bulletin involves evaluating the paint condition on all horizontal panels for etching and using the procedures listed in the Paint Condition Deck p/n 81-316-0507 or using the information listed in this bulletin MODELS: 2006 - (CS) Pacifica **2008** 2006 - (DR/D1/DC/DH) Ram Truck **2008** 2006 - (HB) Durango **2008** **2007 - 2008 (HG) Aspen** 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan **2007 - 2008 (JS) Sebring/Sebring Convertible/Avenger** **2007 - 2008 (JK) Wrangler** **2007 - 2008 (KA) Nitro** Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7870 2006- (KJ) Liberty **2007** **2008 (KK) Liberty 2006 - (LX) 300/Magnum/**Charger** **2008** **2007 - 2008 (MK) Compass/Patriot** 2006- (ND) Dakota **2008** **2007 - 2008 (PM) Caliber** 2006 - (RS) Town & Country/Caravan **2007** **2008 (RI) Town & Country/Grand Caravan** 2006 (TJ) Wrangler 2005 - (WK) Grand Cherokee **2008** 2006 - (XK) Commander **2008** DIAGNOSIS: Inspect the vehicle horizontal panels for the appearance of an etched surface (picture available in "PAINT CONDITION DECK" - publication number 81-316-0507 - see "INSECT ETCH" graphic). Two procedures are available depending on the severity of the condition. Repair Procedure "A" is for conditions that do not show through to primer and Repair Procedure "B" is for conditions that show primer within the etch area. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE "A" FINESSE: 1. Clean with Mopar Car Wash Concentrate, and water. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7871 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. Measure and record paint film thickness in areas to be sanded using an electronic mil gauge (PSE). 5. Use 2000 grit sand paper mounted to a ridged backer to remove all etching. 6. If you remove more than 0.5 mil of clear coat you will need to refinish using repair procedure "B" refinish. 7. If refinishing is not required polish sanded areas using Mopar Compound Power Cleaner # BSMM8432. 8. Remove swirl marks using Mopar Swirl Free polish # BSMM8232. 9. Detail vehicle as required. REPAIR PROCEDURE "B" REFINISH: 1. Clean with Mopar Car Wash Concentrate, and water. 2. Wipe with an alcohol based cleaner 3. Evaluate the paint condition. 4. DA surface with 600 grit sand paper. 5. Clean with appropriate solvent per paint supplier recommendations. 6. Feather edge the damaged areas. 7. Apply corrosion resistant primer to bare metal spots if they exist. 8. Spot prime with primer surfacer. 9. Block sand the primer surfacer. 10. Final sand per paint suppliers recommendations. 11. Clean with appropriate solvent. 12. Tack off the repair area. 13. Apply basecoat with appropriate hardener per paint supplier recommendations. 14. Allow flash time per paint suppliers recommendations and tack off area. 15. Apply clear coat per paint suppliers recommendations. 16. Detail vehicle as required. NOTE: No clear coat spot Repair should be performed on class "A" surfaces. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7872 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 7873 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes PAINT CODES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 7876 Paint: Application and ID Paint Code Location PAINT CODE LOCATION (TYPICAL-ALL MODELS) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description BASECOAT/CLEARCOAT FINISH DESCRIPTION The original equipment paint finish is a multi step process that involves cleaning, applying electro de-position (E-coat), anti-chip primer, basecoat, and clearcoat steps. CAUTION: Do not use abrasive chemicals, abrasive compounds or harsh alkaline based cleaning solvents on the painted surfaces of a vehicle. Failure to follow this caution can result in damage to vehicle finish. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. A clear coat paint is then applied to protect the basecoat from ultraviolet light and to provide a durable high-gloss finish. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 7879 Paint: Description and Operation Paint Code - Description PAINT CODE DESCRIPTION Exterior vehicle body color(s) are identified on the Vehicle Certification Label, Refer to Information Labels or Paint. The first digit of the paint code listed on the vehicle indicates the sequence of application, i.e.: P = primary coat, Q = secondary coat. The color names provided in the Paint and Trim Code Description chart are the same color names used on most repair product containers, Refer to Paint. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP DESCRIPTION If the painted metal surface of a vehicle becomes scratched or chipped, it should be touched-up as soon as possible to avoid corrosion. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Failure to follow this warning may result in possible personal injury or death. When repairing painted metal surfaces, for best results, use MOPAR(R) Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. STANDARD PROCEDURE PAINT TOUCH-UP 1. Scrape any loose paint and corrosion from inside the scratch or chip. WARNING: Avoid prolonged skin contact with petroleum or alcohol-based cleaning solvents. Failure to follow this warning can result in possible personal injury or death. 2. Clean affected area with MOPAR(R) Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, the clearcoat can be lightly finesse sanded (1500 grit) and polished with rubbing compound. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 7882 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING/BUFFING AND POLISHING DESCRIPTION CAUTION: - Do not remove more than 0.5 mils of clearcoat finish when sanding, hand buffing or polishing. Basecoat paint must retain clearcoat for durability. - If the finish has been finesse sanded in the past, it cannot be repeated. Failure to follow this caution can result in damage to vehicle finish. NOTE: Finesse sanding should only be performed by a trained automotive paint technician. Minor acid etching, orange peel, or smudging in a clearcoat or single-stage finish can be reduced with light finesse sanding, hand buffing and polishing. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine clearcoat or single-stage paint thickness before and after the repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair UPPER RADIATOR CROSSMEMBER REMOVAL 1. Remove the hood latch from the upper radiator crossmember (3) and position the latch out of the way. 2. Remove the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator crossmember. 3. Remove the four bolts (1 and 3) that secure the upper radiator crossmember (2) to the fender rails and remove the crossmember. INSTALLATION 1. Position and align the upper radiator crossmember (2) to the fender rails. 2. Install the four bolts (1 and 3) that secure the upper radiator crossmember to the fender rails. Tighten the bolts to 28 N.m (21 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Page 7886 3. Install the bolts (1 and 2) that secure the A/C condenser and the radiator to the upper radiator cross-member (3). Tighten the bolts to 8 N.m (75 in.lbs.). 4. Install the hood latch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7891 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 7892 Module - Sentry Key Remote Entry Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry Keyless Entry Module: Description and Operation Module-Remote Keyless Entry When an RKE lock message is sent to the instrument cluster, the instrument cluster actuates the door locks, the interior lighting is turned off, the horn chirps (if this feature is enabled), the park lamps flash (if this feature is enabled) and, if the vehicle is so equipped, the Vehicle Theft Security System (VTSS) is armed. When an RKE unlock message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. When an RKE panic message is sent to the instrument cluster, the instrument cluster actuates the driver side front door (or all doors if this feature is enabled) unlock, the interior lighting is turned on and, if the vehicle is so equipped, the VTSS is disarmed. The panic message will also cause the exterior lamps (including the headlights) to flash, and the horn to sound for about three minutes, or until a second panic message is sent to the instrument cluster. A vehicle speed of about 25.7 Km/h(15 mph) will also cancel the panic event. Whenever the vehicle battery power is interrupted, the Remote Keyless Module (RKE) Module will retain all vehicle access codes in its memory. When replacing or adding a key fob transmitter (maximum of 4) a scan tool is required to program the RKE Module to accept the new Vehicle Access Code if a customer owned transmitter is not available. If a functioning transmitter is available, refer to Keyless Entry Transmitter. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 7895 Keyless Entry Module: Description and Operation Sentry Key Remote Entry Module The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS) and is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Two SKREEM modules are used: one for vehicles equipped with RKE only, and one for vehicles equipped with RKE and SKIS. The SKREEM cannot be adjusted or repaired. If faulty or damaged, the entire SKREEM unit must be replaced. The Sentry Key REmote Entry Module (SKREEM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver. The SKREEM communicates over the Controller Area Network (CAN) data bus with the ElectroMechanical Instrument Cluster (EMIC), the Powertrain Control Module (PCM)/Engine Control Module (ECM), the Gateway module (SRT10 vehicles with a hybrid bus only) and the diagnostic scan tool. The SKREEM and the PCM/ECM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM/ECM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM/ECM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM or ECM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM or ECM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using a diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the On position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then listens for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends a valid key message to the PCM/ECM over the CAN bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Module-Remote Keyless Entry > Page 7896 SKREEM sends an invalid key message to the PCM/ECM. The PCM/ECM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM or ECM is an invalid key; therefore, if no message is received from the SKREEM by the PCM or ECM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends security indicator status messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator status message from the SKREEM tells the EMIC to turn the indicator on for about three seconds each time the ignition switch is turned to the On position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator status messages to the EMIC to turn the indicator off, turn the indicator on, or to flash the indicator on and off. If the security indicator flashes or stays on solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction and/or the SKIS has become inoperative, the security indicator will stay on solid. If the SKREEM detects an invalid key or if a key transponder- related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. The SKIS performs a self-test each time the ignition switch is turned to the On position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The SKREEM can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Description and Operation > Page 7897 Keyless Entry Module: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry Keyless Entry Module: Service and Repair Module-Remote Keyless Entry REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument cluster. 3. Remove remote keyless entry module (2) from instrument cluster (1). INSTALLATION 1. Install remote keyless entry module (2) to instrument cluster (1). 2. Install instrument cluster. 3. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7900 Keyless Entry Module: Service and Repair Sentry Key Remote Entry Module WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7901 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. Remove the screw (3) that secures the SKREEM (1) to the steering column (2). 10. Disengage the antenna ring from around the ignition lock cylinder housing and remove the SKREEM. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7902 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column (2) with the antenna ring oriented around the ignition lock cylinder housing. 2. Install and tighten the screw (3) that secures the SKREEM to the steering column housing. Tighten the screw to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Service and Repair > Module-Remote Keyless Entry > Page 7903 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). 10. Reconnect the battery negative cable. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS) if the SKREEM is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/ module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 7907 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close Sunroof / Moonroof Module: Customer Interest Body - Sunroof Glass Not Flush With Roof/Won't Close NUMBER: 23-040-06 GROUP: Vehicle Performance DATE: September 26, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software. MODELS: 2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF). SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 7916 If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash SUNR" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 7917 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash SUNR" screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close Sunroof / Moonroof Module: All Technical Service Bulletins Body - Sunroof Glass Not Flush With Roof/Won't Close NUMBER: 23-040-06 GROUP: Vehicle Performance DATE: September 26, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software. MODELS: 2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF). SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 7923 If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash SUNR" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 7924 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash SUNR" screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 7925 Motor/Module - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 7926 Sunroof / Moonroof Module: Service and Repair WARNING: THE EXCESSIVE FORCE LIMITATION (EFL) FEATURE MUST BE CALIBRATED ANY TIME A SUNROOF MOTOR/MODULE IS REPLACED WITH A NEW COMPONENT. FAILURE TO PERFORM THIS PROCEDURE COULD RESULT IN VEHICLE DAMAGE AND/OR PERSONAL INJURY. REMOVAL 1. Move glass panel to the fully closed position. 2. Disconnect and isolate the battery negative cable. 3. Remove headliner. 4. Disconnect the sunroof wire harness electrical connector. 5. Disconnect the four drain tubes (1) from sunroof housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 7927 6. With the aid of a helper, support the sunroof and remove the eight fasteners (2) attaching sunroof assembly (1) to roof panel. 7. Remove the sunroof (1) from vehicle. INSTALLATION 1. Verify that glass panel is loose and slightly retracted. 2. Raise sunroof module assembly (1) and guide it carefully into position. 3. Hand start the eight screws (2). 4. Line up the locating holes and tighten the attaching screws (2) to 9 N.m (80 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 7928 5. Connect the electrical connector (1). 6. Connect the drain tubes (1) to the sunroof. 7. Adjust the sunroof glass. 8. Connect battery negative cable. 9. Install the vehicle headliner. 10. Perform the sunroof position calibration. See: Roof and Associated Components/Sunroof / Moonroof/Testing and Inspection/Programming and Relearning/Sunroof Position Calibration 11. Perform the Excessive Force Limitation (EFL) calibration. 12. Verify proper operation of the power sunroof system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair Sun Shade: Service and Repair REMOVAL 1. Remove the drain channel. 2. Push up the front center of the sunshade (1) to pop out the front two feet. 3. Rotate the sunshade (2) so that the other feet (1) are removed from the guide track. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Page 7934 1. Verify the sunshade track is free of obstructions like the trim lace/ring. 2. Start with sunshade (2) at an angle with one foot (1) in the track. 3. Rotate the sunshade so the other rear foot is in the track as well as the 2 other feet (3) on the same side as the first foot. 4. To insert the remaining two feet (2) apply force to the middle front of sunshade (3) and guide them into the track. 5. Check that all the feet are in the right track and verify sunshade operation. 6. Install the drain channel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7943 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7944 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7945 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7946 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7952 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7953 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7954 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7955 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: Customer Interest Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7964 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7965 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7966 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7967 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof Sunroof / Moonroof Cable Housing: All Technical Service Bulletins Body - Ratcheting Noise When Operating Sunroof NUMBER: 23-004-08 GROUP: Body DATE: January 16, 2008 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 23-045-06 DATED OCTOBER 14, 2006 AND 23-51-06 DATED NOVEMBER 4, 2006. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF WH/XH/L2 MODELS AND 2008 MODEL YEAR VEHICLES. SUBJECT: Ratcheting Sound During Sunroof Operation OVERVIEW: This bulletin involves replacing the sunroof drive cable conduit. MODELS: 2004 - **2008** (DR) Ram Truck **2007 (L2) 300C (China)** 2005 - **2008** (LE) 300C/300C Touring (International Markets) 2005 - 2008 (LX) 300/Charger/Magnum **2005 - 2008 (WH) Grand Cherokee (International Markets)** 2005 - **2008** (WK) Grand Cherokee **2006 - 2008 (XH) Commander (International Markets)** 2006 - 2008 (XK) Commander NOTE: This bulletin applies to DR/L2/LE/LX/WH/WK models with a Power Sunroof (sales code GWA) built before October 31, 2007 (MDH1031XX) and XH models with a Power Sunroof (sales code GWF) built before December 19, 2007 (MDH1219XX) and XK models with a Power Sunroof (sales code GWF) built before November 07, 2007 (MDH1107XX). SYMPTOM/CONDITION: A ratcheting sound is heard from sunroof module as the glass approaches the full open position. DIAGNOSIS: Lower the headliner to view the rear of the sunroof module assembly. Inspect the cable conduit tube(s) located at the rear corners of the sunroof module assembly for a kinked condition. Kinked condition most frequently occurs at passenger rear corner. If a kinked conduit is discovered, perform the appropriate Repair Procedure based on the vehicle below. PARTS REQUIRED: REPAIR PROCEDURE - DRIL2/LE/LX/WH/WK: 1. Ensure the sunroof module is in the full closed position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7973 2. Remove M6 mounting bolts (4) at rear portion of sunroof module. 3. Remove the kinked cable conduit(s) from sunroof module retaining features starting from the end at the metal clip and work back to motor area, see (Fig 1). 4. Assemble new cable conduit, p/n 68003812AA, in reverse order of Step # 3) by inserting the flared end over the exposed end of the drive cable. Insure the flared end is sitting in the notch on the rear bulk head of sunroof module, (Fig 2). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7974 5. Snap the cable conduit into the retaining features in the rear bulk head (5 places) with the end of the tube retained in spring clip on the aluminum guide. Ensure the clip is within the provided scribe lines on aluminum guide, (Fig 3). 6. Torque the mounting bolts to 9 Nm (80 in. lbs.). 7. Operate Sunroof module. 8. Install headliner. REPAIR PROCEDURE - XH/XK: 1. Put the sunroof in the closed or vent position. 2. Drop headliner right front corner, by removing the right side A-pillar trim, B-pillar trim sun visor, sun visor clip and rear view mirror. 3. Look at and/or feel the drive cable conduit in the radius above the drain hose this is where the conduit will be kinked. 4. Remove 2 sunroof mounting fasteners, (Fig 4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7975 5. Remove conduit from clip at side of sunroof module, (Fig 5). 6. Push the conduit up and inboard to release it from the retention feature on the front beam, (Fig 6) item 4. 7. Push the conduit up to release it from the additional retention features, (Fig. 6) item 2. 8. Pull the conduit out from over/off the drive cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Cable Housing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Cable Housing: > 23-004-08 > Jan > 08 > Body - Ratcheting Noise When Operating Sunroof > Page 7976 9. Slide the new conduit, p/n 68003816AA, back over the drive cable. See (Fig. 6) item 1, to ensure conduit is seated into notch to the rear of the steel drive cable tube. 10. Secure the conduit in the retention features shown in (Fig. 6). 11. Install the conduit in the side clip. 12. Operate the sunroof to ensure the ratcheting noise is eliminated. 13. Install the mounting bolts. 14. Install the headliner, A-pillar trim, sun visor and visor clip. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams Motor/Module - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Diagrams > Page 7980 Sunroof / Moonroof Motor: Testing and Inspection Any diagnosis of the power sunroof system should begin with the use of a scan tool and the proper Diagnostic Procedures Information. The scan tool can provide confirmation that the Controller Area Network (CAN) Data Bus is functional, that all of the electronic modules are sending and receiving the proper messages on the CAN Data Bus, and that the power sunroof motor is being sent the proper hard wired output by the sunroof switch. Refer to the appropriate diagnostic information. NOTE: If there is no sunroof movement when the "OPEN" or "CLOSED" button are pushed but the sunroof operates when the "VENT" button is pushed and held the sunroof motor/module is out of calibration. Complete the sunroof position calibration procedure prior to performing any sunroof diagnostics. The wire harness connectors for the sunroof motor/module are located above the vehicle headliner. Removal of the headliner may be necessary for access to the connector and proper diagnosis of the motor/module. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Verify that all other power accessories are in proper operating condition. If not, a common electrical problem may exist. 2. Disconnect the sunroof motor/module connector directly at the motor/module (not at the headliner in-line connector). Connect a test light between the harness connector pin 6 and a known good B+ circuit. The test light should illuminate brightly. If OK, go to Step 3. If not OK repair the ground circuit as necessary. 3. Connect a test light between the harness connector pin 8 and a known good ground. The test light should illuminate brightly. If OK, go to Step 4. If not OK repair the B+ circuit as necessary. 4. Using an ohmmeter check the sunroof switch feed circuit for continuity between the sunroof motor/module and sunroof switch. Continuity should be present. If OK replace the inoperative motor/module. If not OK repair the sunroof switch feed circuit as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Procedures Sunroof / Moonroof Motor: Procedures Initialization NOTE: Verify the battery is in good condition prior to performing this procedure. Do not leave the vehicle on a battery charger while performing this procedure. If the voltage at the sunroof motor/module drops below 11 volts or exceeds 15 volts at anytime while this procedure is being performed, the motor/module initialization procedure will not be properly completed. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for at least 1 second. 3. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of four sunroof closes. 4. Press the vent button on the power sunroof switch and release. The sunroof glass panel should move to the full vent position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the second sunroof closed position in a series of four sunroof closes. 5. Continue to move the sunroof glass to the "vent" then "closed" positions two more times so that the sunroof glass has moved to the closed position a total of four times starting with the first sunroof close in step 3. 6. Press the open position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full open position. 7. Press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. This will be considered the first sunroof closed position in a series of five sunroof closes. 8. Press the open position on the power sunroof switch and release. The sunroof glass panel should move to the full open position. After the sunroof motor/module has stopped, press the close position on the power sunroof switch and release. The sunroof glass panel should continue travel to the full closed position. Continue to move the sunroof glass to the "open" then "closed" position four more times so that the sunroof glass has moved to the closed position a total of five times starting with the first sunroof close in step 7. Verify proper EFL calibration by placing a standard pencil at the front of the sunroof and then moving the sunroof to the full closed position. The sunroof should reverse direction upon contact without damage to the pencil. Sunroof Position Calibration Press the power sunroof switch (Open, Closed, and Vent). If no movement occurs when either the open switch or closed switch is pressed, but the system does move when the vent button is pressed and held, the system is not calibrated. Perform the following procedure to position calibrate the power sunroof system. 1. Turn the ignition to the RUN position. 2. Press the vent button on the power sunroof switch and hold until the sunroof glass panel has moved to the full vent position and the motor movement has stopped for at least 1 second. 3. Press the close switch on the power sunroof switch and hold for a moment (at least 100ms) and release. The sunroof glass panel should continue travel to the full close position. If the sunroof glass panel does not return to the full close position, refer to the appropriate diagnostic information for full system diagnosis. 4. Verify proper system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Procedures > Page 7983 Sunroof / Moonroof Motor: Removal and Replacement WARNING: - DO NOT ATTEMPT TO MOVE OR REPOSITION THE SUNROOF GLASS PANEL OR DRIVE CABLES WITH THE MOTOR/MODULE REMOVED. VEHICLE/SUNROOF DAMAGE OR PERSONAL INJURY MAY RESULT. - THE SUNROOF MUST FIRST BE CALIBRATED AND THE MOTOR/MODULE INITIALIZATION PROCEDURE MUST BE COMPLETED ANY TIME A SUNROOF MOTOR/MODULE IS REPLACED WITH A NEW COMPONENT. FAILURE TO PERFORM THIS PROCEDURE COULD RESULT IN VEHICLE DAMAGE AND/OR PERSONAL INJURY. REMOVAL 1. Disconnect the battery negative cable. 2. Remove the vehicle headliner. 3. Remove the power sunroof motor/module electrical connector (2). 4. Remove the retaining screws (3) and remove the motor/module (1) from the vehicle. INSTALLATION 1. Position the power sunroof motor/module (1) in the vehicle. 2. Install the motor/module retaining screws (3). Tighten the screws to 4 N.m (35 in. lbs.). 3. Connect the motor/module electrical connector (2). 4. Partially install the vehicle headliner and connect all remaining sunroof electrical connectors. 5. Connect the battery negative cable. 6. Perform the sunroof position calibration. See: Testing and Inspection/Programming and Relearning/Sunroof Position Calibration 7. Perform the Motor/Module Initialization Procedure. See: Procedures/Initialization 8. Complete the vehicle headliner installation. 9. Verify proper operation of the power sunroof system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Headliner Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7987 Switch - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7988 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination pushbutton and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Page 7989 Sunroof / Moonroof Switch: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair Sunroof / Moonroof Track: Service and Repair REMOVAL 1. Move the glass panel to the full closed position. 2. Slide sunshade rearward to the open position. 3. Separate the mechanism covers (2) from the tabs (1) on the glass panel. 4. Hold both mechanism covers down and open the sunroof fully. 5. Slide the mechanism covers (1) out the front of the guide in the frame (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Track > Component Information > Service and Repair > Page 7993 1. With the sunroof in the open position, snap the mechanism cover (2) into the lower guide channel. 2. Hold down each cover and close the sunroof. 3. Snap the upper portion of the cover (2) into the retaining clips (1) on the glass panel between the locating features. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair Sunroof / Moonroof Windguard: Service and Repair REMOVAL 1. Open the sunroof fully. 2. Remove the strap screws (2) from the beam area release the strap (3). 3. Rotate the deflector up and remove springs (2) from the holes in the frame (1). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Page 7997 1. Position the deflector spring arms (2) into the holes of the frame (1). 2. Rotate the deflector down, attach the straps (3) and install the strap screws (2) into the front beam. 3. Verify sunroof operation and alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain Sunroof / Moonroof Drain: Service and Repair Channel-Drain CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. REMOVAL 1. Remove glass panel. 2. Separate the drain channel arms (2) from the guide mechanisms (1) one at a time. 3. Carefully slide the drain channel (1) forward to the notches (2) in the frame and remove from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain > Page 8002 1. Carefully position the drain channel (1) into the notches (2) in the frame and slide rearward. 2. Install the drain channel arms (2) into the mechanism (1) holes one at a time with the reinforcements on the inside of mechanism arms. 3. Install the sunroof glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain > Page 8003 Sunroof / Moonroof Drain: Service and Repair Hose-Drain FRONT HOSES REMOVAL 1. Remove headliner. 2. Disconnect the drain hose from the sunroof housing (1). 3. Separate the lower tube from the grommet in the body (3). 4. Drain any liquid from hose connection, if necessary. 5. Release the clips (2) and remove the tube. INSTALLATION 1. Position the lower portion through the grommet in the body (3). 2. Connect the new drain tube to the sunroof housing (1) and test drainage. 3. Position the tube support clips (2) and seat fully. 4. Install headliner. REAR HOUSING HOSE REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Channel-Drain > Page 8004 1. Remove headliner. 2. Disconnect the drain hose from the sunroof housing (1). Front tube shown, rear tube similar. 3. Drain any liquid from hose connection, if necessary. 4. Release the push pin fasteners (2) and separate the lower tube from the grommet in the body (3). INSTALLATION 1. Install the rear tube and seat the push pin fasteners (2) fully. Front tube shown, rear similar. 2. Position the lower portion through the grommet in the body (3). 3. Connect the new drain tube to the sunroof housing (1) and test drainage. 4. Install headliner. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair Sunroof / Moonroof Interior Trim Panel: Service and Repair REMOVAL 1. Remove the headliner. 2. Remove the 12 nuts (1) and roll the trim ring off the headliner off the retaining flanges (2). INSTALLATION 1. Position trim ring support flanges (2) over the headliner and seat the trim ring fully. 2. Install the 12 nuts (1) onto the support studs. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close Sunroof / Moonroof Module: Customer Interest Body - Sunroof Glass Not Flush With Roof/Won't Close NUMBER: 23-040-06 GROUP: Vehicle Performance DATE: September 26, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software. MODELS: 2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF). SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 8016 If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash SUNR" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 8017 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash SUNR" screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close Sunroof / Moonroof Module: All Technical Service Bulletins Body - Sunroof Glass Not Flush With Roof/Won't Close NUMBER: 23-040-06 GROUP: Vehicle Performance DATE: September 26, 2006 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: FLASH: Rear Of Sunroof Glass Is Not Flush To Roof/Sunroof Will Not Close OVERVIEW: This bulletin involves selectively erasing and reprogramming the Sunroof Module (SUNR) with new software. MODELS: 2006 (DR) Ram Truck 2005 - 2006 (LE) 300C/300C Touring 2004 - 2006 (LX) 300/Charger/Magnum 2005 - 2006 (WH) Grand Cherokee (International Markets) 2005 - 2006 (WK) Grand Cherokee 2006 (XH) Commander (International Markets) 2006 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a sunroof (sales code GWA or GWF). SYMPTOM/CONDITION: DIAGNOSIS: 1. Verify the rear of the sunroof glass to roof flushness concern. 2. UNCALIBRATE THE SUNROOF. a. Insure the battery is at least 12 Volts. b. Place the ignition switch in RUN position. c. Locate the sunroof fuse (Fuse 44 in the Power Distribution Center located in the trunk). d. While the sunroof is still in motion, have an assistant remove the sunroof fuse. e. Reinstall the sunroof fuse. 3. RECALIBRATE THE SUNROOF a. Press and hold the sunroof vent switch until it stops at the full vent position. b. Verify sunroof operation by opening, closing, and venting the sunroof. c. If the uncalibrate/recalibrate procedure corrected the sunroof glass to roof fit, perform the Repair Procedure. 4. If the uncalibrate/recalibrate procedure did not eliminate the sunroof glass to roof fit, use the procedures outlined in TechCONNECT(R) BODY/SUNROOF/GLASS PANEL/ADJUSTMENTS to adjust the glass panel. If the sunroof glass is now flush, perform the Repair Procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 8023 If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.02 or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the Repair Procedure. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Select "ECU View" 6. Touch the screen to highlight the SUNR in the list of modules. 7. Select "More Options" 8. Select "ECU Flash" 9. Record the part number at the top of the "Flash SUNR" screen for later reference. 10. Select "Browse for New File". Follow the on screen instructions. 11. Highlight the appropriate calibration then select "Download to Scantool". 12. Select "Close" after the download is complete, then select "Back". Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Module: > 23-040-06 > Sep > 06 > Body - Sunroof Glass Not Flush With Roof/Won't Close > Page 8024 13. Highlight the listed calibration. 14. Select "Update Controller". Follow on screen instructions. 15. When the update is complete, select "OK". 16. Verify the part number at the top of the "Flash SUNR" screen has updated to the new part number. NOTE: Due to the SUNR programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 17. Insure the battery is at least 12 Volts. 18. Place the ignition switch in RUN position. 19. Close all of the doors and windows. 20. Press and hold the vent switch until the sunroof glass moves to the full open vent position. 21. Cycle the sunroof from the full vent open position to the full slide open position and back to the full vent open position at least 7 complete times. The sunroof is now in customer mode with the obstacle detection thresholds updated. 22. Remove the charger from the battery. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 8025 Motor/Module - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 8026 Sunroof / Moonroof Module: Service and Repair WARNING: THE EXCESSIVE FORCE LIMITATION (EFL) FEATURE MUST BE CALIBRATED ANY TIME A SUNROOF MOTOR/MODULE IS REPLACED WITH A NEW COMPONENT. FAILURE TO PERFORM THIS PROCEDURE COULD RESULT IN VEHICLE DAMAGE AND/OR PERSONAL INJURY. REMOVAL 1. Move glass panel to the fully closed position. 2. Disconnect and isolate the battery negative cable. 3. Remove headliner. 4. Disconnect the sunroof wire harness electrical connector. 5. Disconnect the four drain tubes (1) from sunroof housing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 8027 6. With the aid of a helper, support the sunroof and remove the eight fasteners (2) attaching sunroof assembly (1) to roof panel. 7. Remove the sunroof (1) from vehicle. INSTALLATION 1. Verify that glass panel is loose and slightly retracted. 2. Raise sunroof module assembly (1) and guide it carefully into position. 3. Hand start the eight screws (2). 4. Line up the locating holes and tighten the attaching screws (2) to 9 N.m (80 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Technical Service Bulletins > Page 8028 5. Connect the electrical connector (1). 6. Connect the drain tubes (1) to the sunroof. 7. Adjust the sunroof glass. 8. Connect battery negative cable. 9. Install the vehicle headliner. 10. Perform the sunroof position calibration. See: Testing and Inspection/Programming and Relearning/Sunroof Position Calibration 11. Perform the Excessive Force Limitation (EFL) calibration. 12. Verify proper operation of the power sunroof system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments 1. Move the sunshade rearward to the open position. 2. Separate the mechanism covers (2) from the tabs (1) on the glass panel. 3. Verify the sunroof glass panel is in the fully closed position. 4. Loosen the forward attaching screws (3) on each side enough to permit the front of the glass to adjust up or down. 5. Adjust the front surface of the sunroof glass panel 0.00 mm to 2 mm (0.00 in. to 0.08 in.) below the top surface of the roof. 6. Tighten the front glass panel attaching screws to 3.5 N.m (30 in. lbs.). 7. Loosen the rear screws (3) on each side enough to make the rear adjustment. 8. Adjust the rear surface of the sunroof glass panel 0.00 mm to 2 mm (0.03 in. to 0.08 in.) above the top surface of the roof. 9. Tighten the rear glass panel attaching screws to 3.5 N.m (30 in. lbs.). 10. Check for proper fit. If not OK, repeat glass panel adjustment. 11. Position the mechanism covers (2) over the glass tabs (1) between the locating features and seat fully. 12. Verify sunroof operation and alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Glass Sunroof / Moonroof Panel: Service and Repair Glass REMOVAL 1. Move the glass panel to the full closed position. 2. Slide sunshade rearward to the open position. 3. Separate the mechanism covers (2) from the tabs (1) on the glass panel. 4. Remove the glass panel screws (3). 5. Lift off glass panel and remove from vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Glass > Page 8034 1. Position glass panel on to mechanism lift arms. CAUTION: Verify that the retaining tabs are located on the INSIDE of the guide mechanism arms. 2. Start the attaching screws (3). 3. Connect a 12v power supply and verify that the sunroof is in the closed position. 4. Adjust sunroof glass to fit flush with roof line. 5. Tighten the screws (3) to 3.5 N.m (30 in. lbs.). 6. Position the mechanism covers (2) over the glass tabs (1) between the locating features and seat fully. 7. Verify sunroof operation and alignment. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Glass > Page 8035 Sunroof / Moonroof Panel: Service and Repair Guide-Sunroof Glass REMOVAL 1. Place the sunroof in the vent position. 2. Remove the sunroof assembly. 3. Remove the motor. 4. Remove the glass. 5. Remove the wind deflector. 6. Separate the drain channel arms (2) from the guide mechanisms (1) one at a time. CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. 7. Slide the drain channel rearward out of the way. 8. Remove the hard stop screw from the frame. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Glass > Page 8036 9. Push the drive cable and guide plate forward past the hard stop screw location until the glass guide comes loose. 10. Rotate the guide (1) up and out of the front beam (3) and release the front foot (2) from the channel guide. INSTALLATION 1. With the drive cable plate aligned insert the front foot (2) into the guide channel and engage the feet with the front beam (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Glass > Page 8037 2. Rotate the guide plate (1) inboard until the feet of the guide are engaged into the front beam (2). 3. Push the guide assembly (1) and drive cable rearward past the hard stop location. 4. Install the hard stop screw (2) and push the drive cable and guide assembly (1) up against the hard stop screw (2). 5. Verify that the opposite guide assembly is also positioned up against the hard stop screw. 6. Install the wind deflector as necessary. 7. Install the motor as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Glass > Page 8038 8. Install the drain channel arms (2) into the mechanism (1) holes one at a time with the reinforcements on the inside of mechanism arms. CAUTION: Do not pry the channel arms apart at the same time or you could break the drain channel. 9. Install the sunroof assembly into the vehicle. 10. Perform the sunroof position calibration. See: Testing and Inspection/Programming and Relearning/Sunroof Position Calibration 11. Perform the Excessive Force Limitation (EFL) calibration. 12. Install the glass as necessary. 13. Adjust sunroof glass to fit flush with roof line. 14. Verify proper operation of the power sunroof system. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Head Rest: Service and Repair Headrest HEADREST REMOVAL 1. Raise the headrest. 2. Press the headrest release button and remove the headrest. INSTALLATION 1. Position the headrest. 2. Press the release button and install the headrest. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 8044 Head Rest: Service and Repair Headrest Sleeve HEADREST SLEEVE REMOVAL 1. Remove the headrest. 2. Grasp the sleeves and pull up and out of the seat back to remove. INSTALLATION 1. Position each headrest sleeve into correct seat back hole and press into place fully. 2. Install the headrest. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions Memory Positioning Systems: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8049 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8050 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8051 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8052 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8053 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8054 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8055 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8056 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8057 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8058 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8059 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8060 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8061 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8062 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8063 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8064 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8065 Memory Positioning Systems: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8066 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8067 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Diagrams > Diagram Information and Instructions > Page 8068 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 8072 Passenger Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 8073 Power Seat Motor: Diagrams Motor-Lumbar - Driver Motor-Lumbar - Passenger Motor-Seat Adjuster - Driver Horizontal Motor-Seat Adjuster - Front Driver Vertical Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 8074 Motor-Seat Adjuster - Front Passenger Vertical Motor-Seat Adjuster - Passenger Horizontal Motor-Seat Adjuster - Rear Driver Vertical Motor-Seat Adjuster - Rear Passenger Vertical Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt - Driver Switch-Seat - Driver Switch-Seat - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8081 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8082 Power Seat Switch: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If OK, refer to Power Seat Track/Testing and Inspection. If not OK, replace the inoperative power seat switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 8083 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Diagrams Seat Cushion: Diagrams Heater-Seat Cushion - Driver Heater-Seat Cushion - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams Seat Heater: Diagrams Heater-Seat Back - Driver Heater-Seat Back - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats Seat Heater: Description and Operation Heated Seats WARNING: THE FRONT PASSENGER SEAT ASSEMBLY CONTAINS CRITICAL COMPONENTS THAT AFFECT THE FRONT PASSENGER AIRBAG DEPLOYMENT. CORRECTLY FUNCTIONING FRONT PASSENGER SEAT COMPONENTS ARE CRITICAL FOR THE OCCUPANT CLASSIFICATION SYSTEM (OCS) TO PROPERLY CLASSIFY THE FRONT PASSENGER AND CALCULATE THE PROPER AIRBAG DEPLOYMENT. UNAPPROVED MODIFICATIONS OR SERVICE PROCEDURES TO THE FRONT PASSENGER SEAT ASSEMBLY, ITS RELATED COMPONENTS, OR TRIM COVER MAY INADVERTENTLY CHANGE THE AIRBAG DEPLOYMENT IN CASE OF A FRONTAL CRASH. THIS COULD RESULT IN DEATH OR SERIOUS INJURY TO THE FRONT SEAT PASSENGER IF THE VEHICLE IS INVOLVED IN AN ACCIDENT. THE FOLLOWING REQUIREMENTS MUST BE STRICTLY ADHERED TO: - DO NOT MODIFY THE FRONT PASSENGER SEAT ASSEMBLY OR COMPONENTS IN ANY WAY. - DO NOT MODIFY THE FRONT SEAT CENTER CONSOLE OR CENTER POSITION SEAT IN ANY WAY. - DO NOT USE PRIOR OR FUTURE MODEL YEAR SEAT TRIM COVERS NOT DESIGNATED FOR THE SPECIFIC MODEL BEING REPAIRED. ALWAYS USE THE CORRECT SEAT TRIM COVER SPECIFIED FOR THE VEHICLE. - DO NOT REPLACE THE SEAT TRIM COVER WITH AN AFTERMARKET TRIM COVER. - DO NOT ADD A SECONDARY TRIM COVER OTHER THAN THOSE APPROVED BY DAIMLERCHRYSLER/MOPAR. - AT NO TIME SHOULD ANY SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENT OR SRS RELATED COMPONENT OR FASTENER BE MODIFIED OR REPLACED WITH ANY PART EXCEPT THOSE WHICH ARE APPROVED BY DAIMLERCHRYSLER/MOPAR. Vehicles with the heated seat option can be visually identified by the two heated seat switches located in the center stack of the instrument panel. The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system for this vehicle includes the following major components: - Heated Seat Switch/Module - Two heated seat switch/modules are used per vehicle, including two Light-Emitting Diode (LED) indicator lamps for heat level indication. One switch/module for the driver and one for the passenger front seats. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. The switch/modules are mounted in the front center floor console. - Heated Seat Elements - Four heated seat elements are used per vehicle, one for each front seat back and one for each front seat cushion. The elements are integral to the individual front seat and seat back cushions and cannot be removed from the cushions, once installed at the factory. The heated seat system operates on battery current received through a fuse in the Totally Integrated Power Module (TIPM). Fused ignition switch output (run) circuits are used, so that the heated seat system will only operate when the ignition switch is in the On position. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except On. A Heated Seat Switch/Module is used to control the heated seat system. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDs) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats > Page 8092 The system will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats > Page 8093 Seat Heater: Description and Operation Heater-Seat Element Vehicles equipped with the optional heated seat system have two, carbon fiber heated seat elements, located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat element consists of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated seat elements are captured between the leather trim cover and the seat cushion assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element assembly must be installed. One end of the heated seat element is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element by the heated seat switch/module. The heated seat switch/module will energize the heated seat element when the heated seat switch/module button is depressed in the Low or High position. As electrical current passes through the heated seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element Seat Heater: Testing and Inspection Heated Seat Element Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors (2&3) for the heating elements are located under the seat (1). NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.8 - 4.8 ohms for a seat cushion element and 4.3 - 5.4 ohms for a seat back element. If OK, refer to testing. If not OK, replace the inoperative heated seat element. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element > Page 8096 Seat Heater: Testing and Inspection Heated Seat System There are two methods of diagnosing the heated seat system. The "HEATED SEAT SYSTEM SELF-DIAGNOSIS" is to be performed when the system is inoperative and one or more of the heated seat switch/module Light Emitting Diode (LED) indicator lamps are flashing. The "HEATED SEAT SYSTEM BASE DIAGNOSIS" is to be performed when the system is inoperative and no LEDs are flashing or lighting when the switch/module buttons are pressed. HEATED SEAT SYSTEM SELF-DIAGNOSIS NOTE: Before testing the individual components in the heated seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. Heated Seat System Self-Diagnosis Table The heated seat system is capable of performing some self-diagnostics. The following table depicts the various monitored failures which will be reported to the vehicle operator or technician by flashing the individual heated seat switch/module Light Emitting Diode (LED) indicator lamps. Refer to the Heated Seat System Self-Diagnosis table for failure identification. The driver side heated seat switch/module indicator lamps will flash if a failure occurs in the driver side heated seat, and the passenger side heated seat switch/module indicator lamps will flash for a passenger side heated seat failure. If a monitored heated seat system failure occurs, the switch/module indicator lamps will flash at a pulse rate of about one-half second on, followed by about one-half second off for a duration of about one minute after the switch/module for the faulty heated seat is depressed in either the Low or High direction. This process will repeat every time the faulty heated seat switch/module is actuated until the problem has been corrected. Before testing the individual components in the heated seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Diagnostic logic is built into the heated seat switch/module to help locate the problem by the most efficient means possible. Anytime a problem is suspected, locate the diagnosis and testing procedure for the component in question and follow the steps until the specific problem is located and resolved. Once the problem is thought to be corrected, verify correct system operation. If the heated seat system is functioning correctly return the vehicle to service. If a problem could not be verified such as not finding anything wrong when following the diagnostic procedure, this is a good indication that a INTERMITTENT problem may be present. You must then attempt to find the intermittent problem, such as moving the heating element within the seat while testing continuity or wiggling the wire harness s/ electrical connectors under the seat while testing continuity. Always, eliminate all other potential problems before attempting to replace the heated seat switch/module. HEATED SEAT SYSTEM BASE DIAGNOSIS NOTE: Before testing the individual components in the heated seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. PRELIMINARY TEST Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element > Page 8097 - If a single LED indicator lamp for one heated seat switch/module does not operate and the heated seat elements heat, replace the switch with the inoperative indicator lamp. - If both LED indicator lamps for a heated seat switch/module operate, but the heated seat elements do not heat, refer to testing to check the suspect heated seat elements. If the elements test OK, proceed to Step 1. - If both seats (driver and passenger) fail to heat and the indicator lamps on the heated seat switch/modules for both seats fail to operate, test the heated seat fuses in the Integrated Power Module (IPM). If the heated seat fuses check OK, go to Step 1. DRIVER HEATED SEAT SWITCH/MODULE 1. Remove the heated seat switch/modules. 2. Connect the battery negative cable. 3. Turn the ignition to the "RUN" position. 4. Check for battery voltage on terminals 4 and 6 of the switch/module connector of the inoperative seat. Battery voltage should be present on both terminals. If OK go to Step 5. If NOT OK repair the open or shorted fused B(+) circuit as required. 5. Check for continuity between ground terminal 1 of the switch/module connector of the inoperative seat and a good ground. If OK go to Step 6. If NOT OK, repair the open or shorted ground circuit as required. 6. Check for continuity between the heated seat element supply circuit terminal 3 of the switch/module connector of the inoperative seat and the heated seat element connector of the inoperative seat. If OK go to Step 7. If NOT OK, repair the open or shorted supply circuit as required. 7. Perform the heated seat element diagnosis for the inoperative seat. See: Heated Seat Element Refer to testing to check the suspect heated seat elements. If the elements test OK, replace the inoperative heated seat switch/module. If NOT OK, replace the inoperative heated seat element PASSENGER HEATED SEAT SWITCH/MODULE 1. Remove the heated seat switch/modules. 2. Connect the battery negative cable. 3. Turn the ignition to the "RUN" position. 4. Check for battery voltage on terminals 4 and 6 of the switch/module connector of the inoperative seat. Battery voltage should be present on both Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element > Page 8098 terminals. If OK go to Step 5. If NOT OK repair the open or shorted fused B(+) circuit as required. 5. Check for continuity between ground terminal 1 of the switch/module connector of the inoperative seat and a good ground. If OK go to Step 6. If NOT OK, repair the open or shorted ground circuit as required. 6. Check for continuity between the heated seat element supply circuit terminal 3 of the switch/module connector of the inoperative seat and the heated seat element connector of the inoperative seat. If OK go to Step 7. If NOT OK, repair the open or shorted supply circuit as required. 7. Perform the heated seat element diagnosis for the inoperative seat. See: Heated Seat Element Refer to testing to check the suspect heated seat elements. If the elements test OK, replace the inoperative heated seat switch/module. If NOT OK, replace the inoperative heated seat element. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 8099 Seat Heater: Service and Repair REMOVAL NOTE: Do not remove the factory installed heating elements (3) from the seat or seat back cushions. The original element is permanently attached and cannot be removed without permanent damage. The replacement heating element is designed to be applied directly on top of the inoperative factory installed heating element. 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate seat cushion,or seat back trim cover. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. INSTALLATION 1. Peel off the adhesive backing on the back of the replacement heating element (2) and stick directly on top of the factory installed heating element (1). CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 8100 2. Connect the new heating element electrical connectors (3&4). 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion, or seat back trim cover. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation Seat Heater Control Module: Description and Operation Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/ module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 8104 Seat Heater Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 8108 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 8109 Seat Heater Switch: Diagrams Switch-Heated Seat - Driver Switch-Heated Seat - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 8110 Seat Heater Switch: Description and Operation Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/ module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 8111 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation Seat Track: Description and Operation The eight-way power seat option includes a power seat track assembly (1) located under each front seat. The power seat track assembly replaces the standard manually operated seat tracks. The lower half of the power seat track is secured at the front with two bolts to the floor panel seat cross member, and at the rear with two bolts to the floor panel. Four nuts secure the bottom of the seat cushion frame to the upper half of the power seat track unit. The power seat track assembly cannot be repaired, and is serviced only as a complete assembly. If any component in this assembly is inoperative or damaged, the entire power seat track must be replaced. The power seat track unit includes three reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward; or, they can be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. The third motor is the horizontal adjustment motor, which moves the seat track in the forward and rearward directions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 8115 Seat Track: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Operate the power seat switch to move all three seat motors in each direction. The seat should move in each of the selected directions. If the power seat track fails to operate in only one direction, move the seat track a short distance in the opposite direction and test again to be certain that the track is not at its travel limit. If the power seat track still fails to operate in only one direction, refer to testing, for power seat switch diagnosis. If the power seat track fails to operate in more than one direction, proceed as follows: 1. Check the power seat fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the circuit as necessary and replace the inoperative fuse. 2. Remove the power seat switch from the seat. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 3. If not OK, repair the open circuit to the integrated power module as required. 3. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 4. If not OK, repair the open circuit to ground as required. 4. Test the power seat switch. If the switch tests OK, check the wire harness between the power seat switch and the motor for shorts or opens. If the circuits check OK, replace the inoperative power seat track (adjuster) assembly. If the circuits are not OK, repair the wire harness as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 8116 Seat Track: Service and Repair REMOVAL 1. Remove the appropriate seat from the vehicle. 2. Remove the power seat switch from the seat. 3. Remove four seat track mounting nuts from cushion pan. 4. Disconnect the power seat electrical connectors and remove the seat track from the seat cushion. 5. Remove the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). INSTALLATION 1. Install the necessary components that must be transferred to the replacement seat track (seat belt buckles, wire harness, etc.). 2. Position the seat track and install the retaining nuts on the seat cushion pan studs. Torque the bolts to 25 N.m. 3. Route and connect the power seat electrical connectors on the seat track and cushion pan. 4. Install the power seat switch on the seat. 5. Install the seat in the vehicle. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Pedal Positioning Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 8121 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 8122 Switch - Adjustable Pedals (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 8123 Pedal Positioning Switch: Service and Repair SWITCH-ADJUSTABLE PEDALS REMOVAL 1. Remove the lower drivers side bezel (4). 2. Disconnect the electrical connector (3) from the adjustable pedal switch (2). 3. Remove the switch (2) from the lower drivers side bezel (4) by squeezing the retaining clips together and pushing the switch outwards. INSTALLATION 1. Install the switch (2) to the lower drivers side bezel (4) by pushing the switch inwards seating the retaining clips to the lower drivers side bezel (4). 2. Reconnect the electrical connector (3) to the adjustable pedal switch (2). 3. Install the lower drivers side bezel (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Power Door Lock Switch: Locations Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 8127 Right Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 8128 Power Door Lock Switch: Diagrams Switch-Door Lock - Passenger Switch-Window/Door Lock - Driver C1 Switch-Window/Door Lock - Driver C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 8129 Power Door Lock Switch: Description and Operation A window/lock switch is used on all models equipped with power locks, power windows, and power mirrors. The window/lock switch houses the following switches: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Mirror Selector Switch - A three-position rocker switch selects the right or left power mirror for adjustment, or turns the power mirror system Off. Power Mirror Adjustment Switches - Four momentary, arrowhead shaped, directional switches allow the driver to adjust the selected power mirror in the Up, Down, Right, or Left directions. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door. This switch also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, there are individual master switches for each passenger door power window. The window/lock switch also incorporates several green Light-Emitting Diodes (LEDs) that illuminate the power lock and power window switch paddles, and the power mirror switch directional buttons to improve switch visibility. The window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single unit. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster input, which allows the instrument cluster to sense the switch position. Based upon the power lock switch input, the instrument cluster controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit. The switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window is labeled "Auto" and includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the master switches. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Power Mirror Switches The power mirror switch circuitry is connected to battery current through a fuse in the TIPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rocker type selector switch has three positions, one to select the right mirror, one to select the left mirror, and a neutral Off position. After the right or left mirror is selected, one of four directional buttons is depressed to move the selected mirror Up, Down, Right or Left. The power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. The Light-Emitting Diode (LED) in the power mirror switch is connected to battery current through the power window circuit breaker in the TIPM on a fused ignition switch output (run-acc) circuit so that the switch directional buttons will be illuminated whenever the ignition switch is in the On or Accessory positions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock Power Door Lock Switch: Testing and Inspection Switch - Power Lock The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit. The power lock switch on the driver side front door trim panel is integral to the window/lock switch. If the power lock switch operates, but the LED is inoperative, check for battery current at the switch with the ignition switch in the On position. If OK, replace the faulty switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the power lock switch from the door trim panel. Disconnect the door wire harness connector for the power lock switch from the switch connector receptacle. 2. Test the power lock switch resistance. See the Power Lock Switch Test chart to determine if the resistance is correct for the switch in each switch position. If not OK, replace the faulty power lock switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock > Page 8132 Power Door Lock Switch: Testing and Inspection Window/Lock Switch The Light-Emitting Diode (LED) illumination lamps for all of the Driver Door Module (DDM) power window, power lock, and power mirror switches receive battery current through the power window circuit breaker in the Totally Integrated Power Module (TIPM). If all of the LED's are inoperative in the DDM, be certain to diagnose the power window system before replacing the switch unit. If only one LED in the DDM is inoperative, replace the faulty DDM. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty DDM. Refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the DDM from the door trim panel. Disconnect the door wire harness connectors for the DDM from the DDM connector receptacles. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > Switch - Power Lock > Page 8133 Driver Door Module Switch Tests 2. Test the DDM switch continuity. See the Driver Door Module Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty DDM as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch - Power Lock Power Door Lock Switch: Service and Repair Switch - Power Lock REMOVAL The power lock switch on the driver side front door trim panel is integral to the window/lock switch. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Switch - Power Lock > Page 8136 Power Door Lock Switch: Service and Repair Switch - Window/Door Lock REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Install switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection Power Mirror Switch: Testing and Inspection The power mirror switch is included with the window/lock switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Page 8140 Power Mirror Switch: Service and Repair REMOVAL The power mirror switch is included with the window/lock switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Locations Center And Driver Seat Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Switch-Seat Belt - Driver Switch-Seat - Driver Switch-Seat - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8147 Power Seat Switch: Description and Operation The power seats on this vehicle can be adjusted in eight different directions, up, down, front up, front down, rear up, rear down, rearward and forward. The power seat switch is located on the outboard side of the seat cushion on the seat cushion side shield. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch assembly must be replaced. When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8148 Power Seat Switch: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Test Table 3. Using an ohmmeter to test the continuity of the power seat switches in each position. Refer to the POWER SEAT SWITCH TEST TABLE. If OK, refer to Power Seat Track/Testing and Inspection. If not OK, replace the inoperative power seat switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 8149 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side shield from the seat. 3. Pull the switch bezel or side shield unit (1) out from the seat far enough to access the switch wire harness connector. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module (2). 4. Remove the screws (3) that secure the power seat switch (2) to the side shield unit (1). INSTALLATION 1. Position the power seat switch (2) on the seat cushion side shield (1) and install the screws (3). 2. Connect the electrical connector. 3. Install the seat cushion side shield on the seat. 4. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Seat Heater Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 8153 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 8154 Seat Heater Switch: Diagrams Switch-Heated Seat - Driver Switch-Heated Seat - Passenger Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 8155 Seat Heater Switch: Description and Operation Momentary contact push button switch/modules mounted in the instrument panel center bezel operate the heated seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated seat system. If any of the heated seat elements are inoperative or damaged one or more of the LED lamps in the switch/ module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are faulty or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. A Heated Seat Switch/Module is used to control the heated seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after two hours of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue indefinitely until the switch/module button is pushed to turn the system off. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 8156 Seat Heater Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. 3. Disconnect the switch/module electrical connectors. 4. Using an appropriate flat bladed tool, remove the heated seat switch/module from the bezel. INSTALLATION 1. Align the tabs of the switch/module to the instrument panel center bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors. 3. Install the instrument panel center bezel. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Headliner Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8160 Switch - Sunroof Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8161 Sunroof / Moonroof Switch: Description and Operation The power sunroof switch (3) is a combination pushbutton and rocker switch module mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/module assembly. The sunroof switch performs the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed) The power sunroof switch is part of the overhead console assembly and cannot be replaced separately. If the switch is damaged or inoperative the overhead console must be replaced. The power sunroof switch is hard wired to the sunroof motor/module assembly. The switch receives battery current from the motor/module when the ignition switch is in the RUN and ACCESSORY positions. When one of the switch positions is pressed it sends battery current back to the motor/module, signaling it to move the power sunroof to the appropriate position. The motor/module will perform one of the following functions: - Power sunroof open (back of switch pushed) - Power sunroof closed (front of switch pushed) - Power sunroof vent (switch center button pushed Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Page 8162 Sunroof / Moonroof Switch: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If completing the appropriate diagnostic information results in the sunroof switch being inoperative, perform the following test prior to switch replacement. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console. 3. Disconnect the power sunroof switch wire harness connector. Power Sunroof Switch Continuity Table 4. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. Refer to the POWER SUNROOF SWITCH CONTINUITY TABLE. If OK, inspect the wiring harness and connectors for damage. Use a scan tool and the proper Diagnostic Procedures Information to complete diagnosis of the power sunroof system. If not OK, replace the overhead console. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations NVH/SOUND DEADENER LOCATIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 8166 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 8167 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 8168 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair FRONT AIR DAM REMOVAL 1. Remove the two outboard screws. 2. Remove the three middle screws and remove the air dam. INSTALLATION 1. Position the air dam onto the bumper and seat the carrot type fasteners fully. 2. Starting at the center screw install the three middle screws. 3. Install the two outboard screws. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Cover > Component Information > Service and Repair Tailgate Cover: Service and Repair COVER REMOVAL 1. Open the tailgate (1) and remove the tailgate liner, if equipped. 2. Remove the ten bolts (2) that secure the tailgate cover (3) to the inside of the tailgate and remove the cover. INSTALLATION 1. Position the tailgate cover (3) onto the inside of the tailgate (1). 2. Install the ten bolts (2) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 3. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Service and Repair Tailgate Hinge: Service and Repair HINGE REMOVAL 1. Remove the tailgate. 2. If required, remove the bushing (3) from each tailgate hinge (1). 3. Remove the two bolts (4) that secure each tailgate hinge (1) to the cargo box (2) and remove the hinge(s) as necessary. INSTALLATION 1. Position the tailgate hinge(s) onto the cargo box (2) as necessary. 2. Install the two bolts (4) that secure each tailgate hinge to the cargo box. Tighten the bolts to 34 N.m (25 ft.lbs.). 3. If removed, install the bushing (3) onto each tailgate hinge. 4. Install the tailgate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch LATCH REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the actuator rod (3) at the control (2) for the latch (1) being serviced. 4. Disconnect the actuator rod from the control. 5. Remove the two bolts (7 and 8) that secure the latch (5) to the tailgate (4) and position the tailgate check cable (6) out of the way. 6. Remove the latch and actuator rod from the tailgate as an assembly. 7. If required, remove the actuator rod from the latch. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 8184 1. If removed, install the actuator rod onto the latch (5) being serviced. 2. Install the latch and actuator rod into the tailgate (4) as an assembly. 3. Position the tailgate check cable (6) onto the tailgate and install the two bolts (7 and 8) that secure the latch and the check cable to the tailgate. Tighten the bolts to 23 N.m (17 ft.lbs.). 4. Locate the actuator rod (3) to the control (2) using the reference mark made during the removal procedure and connect the rod to the control. 5. Position the tailgate cover (4) onto the inside of the tailgate. 6. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 7. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 8185 Tailgate Latch: Service and Repair Tailgate Latch Striker LATCH STRIKER REMOVAL 1. Open the tailgate and using a grease pencil or equivalent, mark the location of the tailgate striker (1) being serviced. 2. Remove the striker from the cargo box (2). INSTALLATION 1. Position the striker (1) onto the cargo box (2) using the reference mark made during the removal procedure. 2. Tighten the striker to 34 N.m (25 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair Tailgate Release Handle: Service and Repair RELEASE HANDLE REMOVAL 1. Open the tailgate and remove the tailgate liner, if equipped. 2. Remove the ten bolts (5) that secure the tailgate cover (4) to the inside of the tailgate and remove the cover. 3. Using a grease pencil or equivalent, mark the location of the actuator rods (3) at the control (2). 4. Disconnect the actuator rods from the control. 5. Remove the two nuts (3) that secure the release handle (1) and the control (2) to the tailgate (4). 6. Remove the control and the release handle from the tailgate. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Release Handle > Component Information > Service and Repair > Page 8189 1. Position the release handle and the control onto the tailgate. 2. Install the two nuts that secure the release handle and control to the tailgate. Tighten the nuts to 7 N.m (60 in.lbs.). 3. Locate the actuator rods (3) to the control (2) using the reference marks made during the removal procedure and connect the rods to the control. 4. Position the tailgate cover (4) onto the inside of the tailgate. 5. Install the ten bolts (5) that secure the tailgate cover to the tailgate. Tighten the bolts securely. 6. If equipped, install the tailgate liner onto the tailgate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair Tailgate Shock / Support: Service and Repair CABLE-CHECK REMOVAL 1. Open the tailgate and locate the tailgate check cable (3) on the left and right of the cargo box below the tailgate striker (1) as necessary. 2. Pry the cable lock tab(s) (4) outward using a screwdriver or flat bladed tool (2) and remove the tailgate check cable(s) from the cargo box. 3. Remove the bolt (1) that secures the tailgate check cable (2) to the left and right side of the tailgate (3) as necessary. 4. Remove the tailgate check cable(s) from the tailgate. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Tailgate > Tailgate Shock / Support > Component Information > Service and Repair > Page 8193 1. Position the tailgate check cable (2) onto the left and right side of the tailgate (3) as necessary. 2. Install the bolt (1) that secures the small end of the tailgate check cable(s) to the tailgate. Tighten the bolt(s) to 23 N.m (17 ft.lbs.). 3. Position the tailgate check cable (3) to the left and right side of the cargo box below the tailgate striker (1) as necessary. 4. Install the large end of the tailgate check cable(s) onto the cargo box. Make sure that the cable lock tab(s) (4) fully engage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair Towing Hook / Bracket: Service and Repair FRONT TOW HOOK ASSEMBLY REMOVAL 1. Remove front bumper. 2. Remove the bolts (2) and remove the tow hook assembly (3). 3. If the vehicle is a Heavy Duty, then remove the bolts (1) and remove the tow hook (2). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Page 8197 1. Install the tow hook assembly (3) and bolts (2) hand tight. 2. If vehicle is a Heavy Duty, install the tow hook (2) and bolts (1) hand tight. 3. Install the front bumper. 4. Line up the tow hooks/tow hook assembly and tighten the bolts to 68 N.m (50 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box Truck Bed: Service and Repair Cargo Box CARGO BOX NOTE: Long cargo box shown in illustration. Short cargo box similar. REMOVAL 1. Remove the screws (1) that secure the fuel filler (2) to the cargo box (3). 2. Remove the fuel filler from the cargo box and position it out of the way. 3. If necessary, remove the fuel filler door from the cargo box. 4. Disconnect the tail lamp wire harness from the underbody wire harness. 5. If necessary, remove the tail lamp units and wire harness from the cargo box. 6. If necessary, remove the tailgate. 7. If necessary, remove the rear bumper. 8. Remove the bolts (3) that secure the cargo box (1) to the frame (2) (six short box, eight long box) and remove the cargo box. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 8202 1. Position the cargo box (1) onto the frame (2) and loosely install the bolts (3) (six short box, eight long box). 2. Align the cargo box to the cab and tighten the bolts to 108 N.m (80 ft.lbs.). 3. If removed, install tail lamp units and wire harness onto the cargo box. 4. Connect the tail lamp wire harness to the underbody wire harness. 5. If removed, install the tailgate. 6. If removed, install the rear bumper. 7. If removed, install the fuel filler door. 8. Position the fuel filler (2) to the cargo box (3). 9. Install the screws (1) that secure the fuel filler to the cargo box. Tighten the screws to 2.2 N.m (20 in.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Truck Bed > Component Information > Service and Repair > Cargo Box > Page 8203 Truck Bed: Service and Repair Cargo Box-Tie Down CARGO BOX-TIE DOWN REMOVAL 1. Remove the two bolts (1) that secure each cargo box tie down (2) to the cargo bed and remove the cleats as necessary. INSTALLATION 1. Position the cargo box tie downs (2) to the cargo box as necessary. 2. Install the two bolts (1) that secure each cargo box tie down to the cargo box. Tighten the bolts to 34 N.m (25 ft.lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove the wiper arms. 2. Disconnect the cowl plenum washer hose from the washer supply hose at the molded plastic in-line fitting. 3. Remove the cowl weather seal from the front of the dash panel and the cowl grille (2). 4. Remove the six push pin fasteners (1) that secure the front of the cowl grille to the dash panel. 5. Remove the two screws (3) that secure the rear corners of the cowl grille to the dash panel and remove the grille. 6. If necessary, remove the washer nozzles and the cowl plenum washer hose from the cowl grille. INSTALLATION 1. If removed, install the washer nozzles and the cowl plenum washer hose onto the cowl grille (2). 2. Position the cowl grille onto the dash panel. 3. Install the two screws (3) and the six push-pin fasteners (1) that secure the cowl grille to the dash panel. 4. Install the cowl weather seal onto the front of the dash panel and the cowl grille. 5. Connect the cowl plenum washer hose to the washer supply hose at the molded plastic in-line fitting. 6. Install the wiper arms. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8214 Front Door Weatherstrip: Service and Repair A-Pillar Weatherstrip Retainer A-PILLAR WEATHERSTRIP RETAINER REMOVAL 1. Remove the drip rail weatherstrip retainer (1). 2. Remove the five screws (8) and remove the A-pillar weatherstrip retainer (7). INSTALLATION 1. Install the A-pillar weatherstrip retainer (7) and install the screws (8). 2. Install the drip rail weatherstrip retainer (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8215 Front Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8216 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8217 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8218 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8219 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8220 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8221 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8222 Front Door Weatherstrip: Service and Repair Drip Rail Weatherstrip Retainer DRIP RAIL WEATHERSTRIP RETAINER REMOVAL 1. Separate the drip rail weatherstrip (3) from the weatherstrip retainer (1). 2. Remove the seven screws (2) and remove the retainer (1). INSTALLATION 1. Install the weatherstrip retainer (1) and install the seven screws (2). 2. Position the weatherstrip (3) over the retainer flange and seat fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8227 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8228 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8229 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8230 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8231 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8232 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8233 2. Install the door trim panel (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip Rear Door Weatherstrip: Service and Repair Drip Rail Weatherstrip DRIP RAIL WEATHERSTRIP REMOVAL 1. Open the doors and separate the weatherstrip (3) from the drip rail and a-pillar retainers (1 and 7). INSTALLATION 1. Position the weatherstrip (3) onto the drip rail and a-pillar retainers (1 and 7) and seat fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8238 Rear Door Weatherstrip: Service and Repair Door Opening Seal DOOR OPENING SEAL REMOVAL FRONT DOOR SEAL 1. Remove the cowl trim panel (1), Refer to Trim Panel. 2. If vehicle is a Standard Cab, remove the lower b-pillar trim panel (3), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8239 3. If vehicle is a Quad Cab, remove the lower b-pillar trim panel (1), Refer to Trim Panel. 4. Separate the front door opening seal (6) from the door opening flange. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8240 1. Remove the lower b-pillar trim panel (1), Refer to Trim Panel. 2. Remove the lower c-pillar trim (1), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8241 3. Separate the rear door opening seal (5) from the door opening flange. INSTALLATION FRONT DOOR SEAL 1. Position the front door seal (6) to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. If vehicle is a Standard Cab, install the lower b-pillar trim (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8242 3. If vehicle is a Quad Cab, install the lower b-pillar trim (1). 4. Install the cowl trim panel (1). NOTE: When installing a new weatherstrip on the front door opening, remove the tear strip starting at the splice and moving around the front of the door to the back of the opening. REAR DOOR SEAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8243 1. Position the rear door seal to the bottom of the door opening, with bulb facing outboard, starting the installation at the center of the lower flange. Press the seal onto the sill flange and work around the perimeter of the door opening until fully seated. Work in one direction, smoothing the seal to avoid puckers or wrinkles. 2. Install the lower c-pillar trim (1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Drip Rail Weatherstrip > Page 8244 3. Install the lower b-pillar trim (1). NOTE: When installing a new weatherstrip on the rear door opening, remove the tear strip starting at the splice and moving around the back of the door to the front of the opening. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8249 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8250 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8251 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8252 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8253 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 8254 2. Install the door trim panel (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8259 Cruise Control Servo: Description and Operation A speed control servo is not used with any 5.7L V-8 engine, or with the 5.9L diesel engine. The speed control servo is attached to the bottom of the battery tray. The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. A speed control servo is not used with any 5.7L V-8 engine, or with the 5.9L diesel engine. The following information applies only to vehicles equipped with a mechanical servo. When/if a servo is used on gasoline powered vehicles, the Powertrain Control Module (PCM) controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly. Power is supplied to the servo's by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded at the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM duty cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. When the brake is released, if vehicle speed exceeds 30 mph to resume, 35 mph to set, and the RES/ACCEL switch has been depressed, ground for the vent and vacuum circuits is restored. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable is used only with 3.7L/4.7L gas powered engines only. A speed control servo cable is not used if equipped with either a 5.9L diesel engine, or any 5.7L engine. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control - Left Switch-Speed Control - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8266 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8267 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Description and Operation Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is a plastic storage tank connected to an engine vacuum source by vacuum lines. A vacuum reservoir is not used with diesel engines or the 5.7L gas powered engine. The vacuum reservoir is used to supply the vacuum needed to maintain proper speed control operation when engine vacuum drops, such as in climbing a grade while driving. A one-way check valve is used in the vacuum line between the reservoir and the vacuum source. This check valve is used to trap engine vacuum in the reservoir. On certain vehicle applications, this reservoir is shared with the heating/air-conditioning system. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams Cruise Control Switch: Diagrams Switch-Speed Control - Left Switch-Speed Control - Right Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8275 Cruise Control Switch: Description and Operation Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Depending on engine control computer (JTEC having a 3- plug connector or NGC having a 4- plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switch used with the NGC system has an attached pigtail lead. The switch used with the JTEC system does not have an attached pigtail lead. When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph. In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM (ECM for diesel). NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's/ECM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM (ECM for diesel) is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's/ECM's RAM when the ACCEL switch is released. The PCM/ECM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for each momentary switch activation of the ACCEL switch. The PCM/ECM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's/ECM's ON, OFF input, and the battery voltage to the brake switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8276 Cruise Control Switch: Service and Repair REMOVAL Depending on engine control computer (JTEC having a 3-plug connector or 5.7L V-8 NGC having a 4-plug connector), 2 types of switches are used. Both types of switches are internally and externally different. The switches used with the NGC system have attached pigtail leads. The switch used with the JTEC system does not have an attached pigtail lead. 1. Remove switch mounting screw (2). 2. Pull switch (2) from steering wheel. 3. Unplug electrical connector from switch, or, switch pigtail wire harness from steering wheel wire harness (4) and remove switch. INSTALLATION 1. Plug electrical connector into switch, or connect pigtail wire harness to steering wheel wire harness. Be sure wires are not pinched. 2. Position switch to steering wheel. 3. Install switch mounting screw and tighten. Refer to torque specifications. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Antilock Brake System ABS Light: Description and Operation Antilock Brake System An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the ABS or Rear Wheel Anti-Lock (RWAL) brake systems, which are not available in some markets. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The ABS indicator gives an indication to the vehicle operator when the ABS system is faulty or inoperative. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ABS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the ABS indicator will be illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for five consecutive message cycles, the ABS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the ABS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator is blinked on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB will each store a DTC. For proper diagnosis of the antilock brake system, the CAB, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ABS indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > Antilock Brake System > Page 8282 ABS Light: Description and Operation Electronic Stability Program/Brake Assist System Indicator An ESP/BAS indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional Electronic Stability Program (ESP)/Brake Assist System (BAS), this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. The ESP/BAS indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/ Brake Assist System (BAS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is illuminated for about four seconds as a bulb test. - ESP/BAS Lamp-On Message - Each time the cluster receives an ESP/BAS lamp-on message from the CAB or the TIPM, the ESP/BAS indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the CAB or TIPM message. The indicator remains illuminated until the cluster receives an ESP/BAS lamp-off message from the CAB or TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and TIPM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or TIPM then sends the proper ESP/BAS lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the ESP/ BAS system, the CAB, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ESP/BAS indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation Audible Warning Device: Description and Operation A chime warning system is standard factory-installed equipment. The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the electronic circuit board inside of the ElectroMechanical Instrument Cluster (EMIC) (1) to provide audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The EMIC also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node or CCN. The electromechanical transducer generates beep tones and chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based EMIC utilizes electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus along with hard wired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the EMIC allow it to control the audible outputs that are produced through its on-board transducer and relay. The EMIC is capable of producing the following audible outputs: - Slow Rate Repetitive Click - Repeated click tones that are issued at a slow rate of about 50 clicks per minute. - Fast Rate Repetitive Click - Repeated click tones that are issued at a fast rate of more than about 100 clicks per minute. - Fixed Duration Beep - A short, sharp, single tactile beep tone. - Single Chime Tone - A single chime tone. - Slow Rate Repetitive Chime - Repeated chime tones that are issued at a slow rate of about 50 chimes per minute. - Fast Rate Repetitive Chime - Repeated chime tones that are issued at a fast rate of about 180 chimes per minute. Hard wired circuitry connects the EMIC and the various chime warning system switch and sensor inputs to their modules and to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the EMIC through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pinout and location views for the various wire harness connectors, splices and grounds. The EMIC chime warning system circuits and components cannot be adjusted or repaired. If the EMIC circuitry, the on-board transducer or the relay are damaged or ineffective, the EMIC unit must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 8286 The chime warning system operates on battery voltage received through a fuse in the Totally Integrated Power Module (TIPM) on a non-switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system also monitors the ignition switch position so that some chime features are functional only with the ignition switch in the ON position, while others are functional regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator or occupants under the following conditions: - Airbag Indicator Warning - The ElectroMechanical Instrument Cluster (EMIC) transducer will generate one short chime when the ignition switch is in the ON position, and an electronic message is received over the Controller Area Network (CAN) data bus from the Occupant Restraint Controller (ORC) requesting airbag indicator illumination. This warning will only occur following completion of the airbag indicator bulb test, and will only occur once during any ignition cycle. - Compass Mini-Trip Computer Global Reset - The EMIC transducer will generate one short chime when the ignition switch is in the ON position, and an electronic message is received over the CAN data bus from the optional Compass Mini-Trip Computer (CMTC) requesting that the CMTC average fuel economy, trip odometer and distance to empty data be reset. The CMTC monitors hard wired inputs from the US/M and RESET button switches to determine the proper reset messages to send to the EMIC. - Door Ajar Indicator Warning - The EMIC transducer will generate one short chime when the ignition switch is in the ON position, a hard wired input is received indicating that the status of any door ajar switch has changed, and an electronic message is received over the CAN data bus indicating that the vehicle is moving. Engine Coolant Temperature High Warning (Diesel Engine Only) - The EMIC transducer will generate a single chime tone when the check gauges indicator is illuminated for a high or critical engine coolant temperature condition. The instrument cluster uses engine coolant temperature message inputs received from the diesel Engine Control Module (ECM) over the CAN data bus to illuminate the check gauges indicator for a coolant temperature high condition. - Fasten Seat Belt Indicator Warning - The EMIC transducer will generate repetitive chimes at a slow rate to announce that a hard wired input from the seat belt switch indicates that the driver side front seat belt is not fastened with the ignition switch in the ON position. The chime warning system also supports the enhanced seatbelt reminder (beltminder) when this feature is enabled. - Head/Park Lamps-On Warning - The EMIC transducer will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the headlamp switch, and the ignition switch indicate that the exterior lamps are turned ON with the driver side front door opened and the ignition switch in the OFF position. The chimes will continue to sound until the exterior lamps are turned OFF, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Key-In-Ignition Warning - The EMIC transducer will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition switch circuitry of the ignition switch indicate that the key is in the ignition lock cylinder with the driver side front door open and the ignition switch in the OFF position. The chimes will continue to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Low Fuel Indicator Warning - The EMIC transducer will generate one short chime when the low fuel indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Low Oil Pressure Warning (Diesel Engine Only) - The EMIC transducer will generate repetitive chimes at a fast rate when the check gauges indicator is illuminated for a low oil pressure condition. The instrument cluster uses engine speed and oil pressure message inputs received from the diesel Engine Control Module (ECM) over the CAN data bus indicating that the engine is running and that the oil pressure is low to illuminate the check gauges indicator. The chimes will continue to sound for five seconds, until the engine oil pressure message indicates that the oil pressure is not low, or until the engine speed message indicates that the engine is not running, whichever occurs first. This chime will only occur once during any ignition cycle. - Low Wash Indicator Warning - The EMIC transducer will generate one short chime when the low washer fluid indicator is illuminated by the instrument cluster circuitry. This chime will only occur once during any ignition cycle. - Overspeed Warning - The EMIC transducer will generate repetitive chimes at a slow rate to indicate that the vehicle speed is over a pre-programmed speed value. The EMIC monitors electronic vehicle speed messages received over the CAN data bus. This feature is only enabled on an EMIC that has been programmed with a Middle East Gulf Coast Country (GCC) country code. - Park Brake Reminder - The EMIC transducer will generate one short chime to announce that the hard wired input from the park brake switch and a vehicle speed message input received over the CAN data bus indicate that the park brake is applied and the vehicle is moving. This chime will repeat each time the input conditions are met. - Sentry Key Customer Learn Mode Announcement - The EMIC transducer will generate one short chime to confirm that an electronic Customer Learn mode message has been received over the CAN data bus to indicate the Sentry Key REmote Entry Module (SKREEM) is prepared for programming additional sentry key transponders. This chime feature is only active on vehicles equipped with the optional Sentry Key system, and sold in a market where Customer Learn programming is an allowed feature. - Trans Overtemp Indicator Warning (Automatic Transmission Only) - The EMIC transducer will generate repetitive chimes at a slow rate when the transmission overtemp indicator is illuminated by the instrument cluster for a high or critical transmission fluid temperature condition. This chime will repeat each time the trans overtemp indicator is cycled from off to on. - Trans Overtemp Indicator Warning (Automatic Transmission Only) - The EMIC transducer will generate repetitive chimes at a slow rate when the transmission overtemp indicator is illuminated by the instrument cluster for a high or critical transmission fluid temperature condition. This chime will repeat each time the trans overtemp indicator is cycled from off to on. - Turn Signal/Hazard Warning Flasher Emulation - The EMIC relay will generate repetitive clicks at a slow rate to emulate an electromechanical flasher when the turn signal or hazard warning system are operating. The EMIC relay will generate repetitive clicks at a fast rate to indicate that the right or left turn signal are operating with one or more bulbs inoperative. In either case, the clicks will continue until the turn signal and hazard warning systems are turned OFF. - Turn Signal On Warning - The EMIC transducer will generate repetitive chimes at a slow rate to indicate that a turn signal has been active continuously for 1.6 kilometers (one mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Page 8287 markets other than the United States and Canada have a revised distance threshold of 4 kilometers for this feature. The chime will continue until the turn signal input becomes inactive or until the vehicle speed message indicates that the speed is less than 22 kilometers-per- hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Indicator Announcement - The EMIC transducer will generate one short chime each time the check gauges indicator is illuminated by the instrument cluster circuitry. The check gauges indicator may be illuminated when any critical engine or transmission systems are operating outside of their normal parameters. The instrument cluster monitors electronic messages received over the CAN data bus to determine when to illuminate the check gauges indicator. The EMIC provides chime service for all available features in the chime warning system. The EMIC relies upon its internal programming, numerous hard wired inputs, and electronic message inputs received from other modules over the CAN data bus network to provide the chime warning system features. The internal programming of the EMIC determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hard wired chime warning system inputs to the EMIC may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic messages received by the EMIC from other modules. The most reliable, efficient and accurate means to diagnose the EMIC, the CAN data bus, or the electronic message inputs used for the chime warning system requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Audible Warning Device: Symptom Related Diagnostic Procedures Chime Sounds With Driver Door Open Key Removed CHIME SOUNDS WITH DRIVER DOOR OPEN KEY REMOVED Chime Sounds With Driver Door Open Key Removed POSSIBLE CAUSES Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8290 - Key-in IGN SW status - Ignition switch shorted - (G26) key-in ignition SW sense short to ground - Cluster DIAGNOSTIC TEST 1. READ KEY-IN IGNITION SWITCH STATUS NOTE: Ensure the exterior lamps turn on and off properly and are off before continuing this test. With the scan tool select: CCN. Read the Key-In Ign Sw. Remove the key from the ignition switch. Q: Does the scan tool show Key-In Ign: False? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. KEY-IN IGN SWITCH SHORTED Disconnect the Ignition Switch connector. Q: Did the chime turn off? YES: Check the Ignition Lock Cylinder for damage. If OK replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 3 3. (G26) KEY-IN IGNITION SWITCH SENSE WIRE SHORT TO GROUND Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8291 Turn ignition off. Disconnect the Ignition Switch connector. Disconnect the Cluster C3 connector. Measure the resistance of the (G26) Key-in Ignition Switch Sense circuit to ground at the Ignition Switch connector. Q: Is the resistance below 100.0 ohms? YES: Repair the (G26) Key-In Ignition Switch Sense wire for a short to ground. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Key In Ignition and Driver S Door Open Chime Inoperative KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME INOPERATIVE Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8292 Key In Ignition And Driver's Door Open Chime Inoperative POSSIBLE CAUSES - (Z42) ground open - (G26) key-in ignition switch open - Ignition switch - Cluster DIAGNOSTIC TEST Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8293 1. READ KEY-IN IGNITION SWITCH STATUS NOTE: The driver's door ajar switch must be operational for the result of this test to be valid. Ensure that the Key is still in the Ignition Switch. With the scan tool select CCN. Read the Key-In Ign Sw. Q: Does the scan tool display Key-In Ign: True? YES: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 2 2. IGNITION SWITCH GROUND CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch connector. Turn all lights off. Measure the resistance between ground and the (Z42) Ground circuit in the ignition switch harness connector. Q: Is the resistance below 5.0 ohms? YES: Go To 3 NO: Repair the (Z42) Ground circuit for an open. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test 3. IGNITION SWITCH OPEN Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8294 Connect the ignition switch connector if disconnected. Turn ignition on. With the ignition switch connector connected, back jumper the (G26) Key-In Ignition Switch Sense circuit to ground at the ignition switch connector. With the scan tool observe the Key-In Ign Sw status. Q: Does the scan tool display Key-In Ign SW: True? YES: Replace the Ignition Switch. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Go To 4 4. KEY-IN IGNITION SWITCH SENSE CIRCUIT OPEN Turn the ignition off. Disconnect the Ignition Switch harness connector. Disconnect the Cluster C3 harness connector. Measure the resistance of the (G26) Key-In Ignition Switch Sense circuit between the ignition switch connector and the Instrument Cluster C3 connector. Q: Is the resistance below 5.0 ohms? YES: Replace and program the Instrument Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Repair the (G26) Key-In Ignition Switch Sense circuit for an open Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8295 Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Chime Inoperative CHIME INOPERATIVE POSSIBLE CAUSES - Cluster DIAGNOSTIC TEST 1. ACTUATE THE CHIME Turn the ignition on. Close the doors. With the scan tool select CCN and actuate the Chime. Q: Does the chime sound when actuated? YES: If the chime operates as it should, check for other reasons that the chime is being inoperative. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Vehicle Speed Warning Chime Problem VEHICLE SPEED WARNING CHIME PROBLEM POSSIBLE CAUSES - Incorrect country code programmed in TIPM - Cluster DIAGNOSTIC TEST 1. WITH THE SCAN TOOL CHECK THE COUNTRY CODE SETTING NOTE: The high speed warning chime is for Gulf Coast Countries only. Turn the ignition on. With the scan tool check the country code setting in the TIPM. Q: Is the country code incorrect? YES: Program the correct country code. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test NO: Replace and program the Cluster. Perform BODY VERIFICATION TEST - VER 1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8296 Audible Warning Device: Component Tests and General Diagnostics Part 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8297 Part 2 WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8298 The hard wired chime warning system inputs to the ElectroMechanical Instrument Cluster (EMIC), as well as other hard wired circuits for this system may be diagnosed and tested using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Area Network (CAN) data bus, or the electronic message inputs used by the EMIC to provide chime warning system service. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and the electronic message inputs for the chime warning system requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component Information > Description and Operation Check Gauges Lamp: Description and Operation A check gauges indicator is standard equipment on all instrument clusters. The check gauges indicator is located on the left side of the instrument cluster, to the left of the voltage gauge. The check gauges indicator consists of a stencil-like cutout of the words CHECK GAGES in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The check gauges indicator is serviced as a unit with the instrument cluster. The check gauges indicator gives an indication to the vehicle operator when certain instrument cluster gauge readings reflect a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The check gauges indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the check gauges indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the check gauges indicator is illuminated for about two seconds as a bulb test. - Engine Temperature High Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine coolant temperature is high, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine coolant temperature is not high, or until the ignition switch is turned to the OFF position, whichever occurs first. Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is low, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is not low, or until the ignition switch is turned to the OFF position, whichever occurs first. The cluster will only turn the indicator on in response to an engine oil pressure low message if the engine speed is greater than zero. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is low (charge fail condition) or that the battery temperature sensor input is an open circuit, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is not low, or until the ignition switch is turned to the OFF position, whichever occurs first. - System Voltage High Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is high, the check gauges indicator will be illuminated and a single chime is sounded. The indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is not high, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the check gauges indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. On vehicles with a diesel engine, the ECM continually monitors the engine temperature, oil pressure, and electrical system voltage, then sends the proper messages to the instrument cluster. For further diagnosis of the check gauges indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the check gauges indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8306 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8307 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8308 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8309 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8310 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8311 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8312 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8313 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8314 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8315 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8316 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8317 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8318 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8319 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8320 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8321 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8322 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8323 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8324 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8325 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8326 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8327 8w-41-3 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8328 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 8329 Cigarette Lighter: Testing and Inspection For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open or short as required. 3. Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continuity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the inoperative cigar lighter knob and element. If not OK, go to Step 5. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the inoperative cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Page 8330 Cigarette Lighter: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Pull the cigar lighter knob and element (1) out of the cigar lighter receptacle base (6), or unsnap the protective cap from the power outlet receptacle base (6). 3. Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangular retaining bosses (3) of the mount that secures the receptacle base to the panel (4). 4. Insert a pair of external snap ring pliers (5) into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount. 5. Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount. 6. Pull the receptacle base away from the instrument panel far enough to access the instrument panel wire harness connector (2). 7. Disconnect the instrument panel wire harness connector (2) from the cigar lighter or power outlet receptacle base (6). 8. Remove the cigar lighter or power outlet mount from the instrument panel. INSTALLATION 1. Connect the instrument panel wire harness connector to the cigar lighter or power outlet receptacle base connector receptacle. 2. Install the cigar lighter or power outlet mount into the instrument panel. 3. Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount. 4. Press firmly on the cigar lighter or power outlet receptacle base until the retaining bosses of the mount are fully engaged in their receptacles. 5. Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation The Electronic Overhead Module (EOM) is located in the overhead console (7) and consists of the following components: - Compass mini-trip computer (on vehicles equipped with this option) - Vacuum-Fluorescent Display (VFD) (6) - Push button function switches (1, 2, 3, 4 and 5) The EOM contains a central processing unit and interfaces with other electronic modules in the vehicle on the Controller Area Network (CAN) data bus. The CAN data bus allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. If any of the components of the EOM are damaged or inoperative the entire EOM must be replaced,. The EOM provides several electronic functions and features. Some of the functions and features that the EOM supports and/or controls, include the following display options: - Compass and temperature - provides the outside temperature and one of eight compass readings to indicate the direction the vehicle is facing. - Trip odometer (TRIP ODO) - shows the distance travelled since the last trip computer reset. - Average fuel economy (AVG ECO) - shows the average fuel economy since the last trip computer reset. - Distance to empty (DTE) - shows the estimated distance that can be travelled with the fuel remaining in the fuel tank. This estimated distance is computed using the level of the fuel in the tank and a weighted average of long term and recent Average Fuel Economy. - Elapsed time (ET) - shows the accumulated ignition-on time since the last trip computer reset. - Blank screen - the compass mini-trip VFD is turned off or in Blank Screen Mode. The ambient temperature sensor is hard wired to the Front Control Module (FCM). The instrument cluster, also known as the Cab Compartment Node (CCN) averages and filters the ambient temperature signal and supplies it to other modules on the CAN data bus. Data input for all other compass mini-trip computer functions, including VFD dimming level, is received through CAN data bus messages. The maximum temperature displayed is 66° C (140° F). It could take several miles for the accurate temperature to be displayed as the CCN filters out heat from the engine compartment. The EOM uses its internal programming and all of these inputs to calculate and display the requested data. If the data displayed is incorrect, perform the self-diagnostic tests as described. If these tests prove inconclusive, the use of a scan tool and the proper Diagnostic Procedures Information are recommended for further testing of the EOM and the CAN data bus. The EOM cannot be repaired, and is available for service only as a unit. This unit includes the push button switches, the Universal Garage Door Transmitter and the plastic module and display lens. If any of these components is inoperative or damaged, the complete EOM must be replaced. COMPASS NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in one or two complete circles, on level ground, in not less than 16 seconds. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 8334 of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, refer to Mini-Trip Computer to restore proper compass operation. TEMPERATURE The temperature displays the outside ambient temperature in whole degrees. The temperature display can be changed from Fahrenheit to Celsius using the U.S./Metric push button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. Displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the Cab Compartment Node (CCN) over the Controller Area Network (CAN) data bus circuit. The CCN then transfers the temperature information to the EOM for display on the vacuum-fluorescent display screen. NOTE: The compass mini-trip computer will display min and max temperatures of -40° C (-40° F) and 54° C (130° F). The compass mini-trip computer only operates with the ignition switch in the On position and the Ignition Off Draw (IOD) fuse functioning and in place. When the ignition switch is turned to the On position, all of the segments in the compass mini-trip computer Vacuum- Fluorescent Display (VFD) will be turned off for one second, then the display will return to the last function being displayed before the ignition was turned to the Off position. With the ignition switch in the On position, momentarily depressing and releasing the Step push button (4) will cause the compass-mini-trip computer to change its mode of operation. Momentarily depressing and releasing the U.S./Metric push button (1) will cause the unit to toggle between U.S. and Metric measurements. Momentarily depressing and releasing the C/T (compass/temperature) push button (5) will cause the compass mini-trip computer to return to the compass/temperature display mode from any other mode. This compass mini-trip computer features several functions that can be reset. If the RESET push button (2) is depressed for more than one second with the ignition switch in the On position, the trip computer information that can be reset is reset. However, the reset will only occur if the function currently displayed is a function that can be reset. The functions that can be reset are: TRIP ODO, AVG ECO, and ET. All three of these functions can be reset at once by pressing the RESET button twice within 3 seconds while any one of the three functions is selected. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Compass/Mini-Trip Computer (CMTC) Self-Diagnostics Compass: Testing and Inspection Compass/Mini-Trip Computer (CMTC) Self-Diagnostics NOTE: The temperature, fuel economy, distance to empty and trip odometer are calculated in the Cab Compartment Node (CCN) and transferred to the Electronic Overhead Module (EOM) for display. If the EOM and Vacuum Fluorescent Display (VFD) test OK testing of the CCN and Controller Area Network (CAN) data bus circuit may be necessary. Refer to the proper Diagnostic Procedures Information to test the CCN and CAN data bus circuit. If the problem with the compass mini-trip computer is an inaccurate or scrambled display, refer to SELF- DIAGNOSTIC TEST. See: CMTC Self-Diagnostic Test If the problem with the compass mini-trip computer is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Cab Compartment Node (CCN) or Front Control Module (FCM) over the Controller Area Network (CAN) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the Totally Integrated Power Module (TIPM). If the IOD fuse is OK and in place, go to Step 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Totally Integrated Power Module (TIPM), repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST See: CMTC Self-Diagnostic Test for further diagnosis of the electronics module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Compass/Mini-Trip Computer (CMTC) Self-Diagnostics > Page 8337 Compass: Testing and Inspection CMTC Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If module is equipped with the Universal Transmitter, the module also checks Universal Transmitter Communication Test Status. 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: - If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. If the first seven tests pass, the compass mini-trip computer shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EOM will automatically return to normal operation after sixty seconds. The EOM can also be returned to normal operation any time during the test by pressing the STEP, CT, RESET or US/M buttons. The required CAN bus messages are: - Dimming message - VIN (Vehicle Identification Number) - Vehicle Speed message - Ignition On Time - Odometer - Trip Odometer - Vehicle Configuration (Model Year, Country and Vehicle Platform) - Fuel Economy - Distance To Empty - Ambient Air Temperature message NOTE: - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection > Page 8338 Compass: Adjustments COMPASS VARIATION ADJUSTMENT Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. To set the compass variance: 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On/Run position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display. 3. Press and hold the Reset push button down until "VAR" appears in the display. This takes about five seconds. 4. Momentarily depress and release the STEP push button to step through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the Reset push button to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp Compass: Service and Repair Illumination Lamp WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: There are provisions for up to three bulb/bulb holder units on the Compass Mini-Trip Computer (CMTC) circuit board. The two outboard bulbs illuminate the CMTC push buttons, while the center bulb illuminates the optional universal transmitter push buttons. Therefore, the center bulb location is only populated on vehicles equipped with the optional universal transmitter. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Compass Mini-Trip Computer (CMTC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 8341 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Compass Mini- Trip Computer (CMTC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 8342 Compass: Service and Repair Calibration CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement compass mini-trip computer modules must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variation number must also be reset. See Compass Variation Adjustment. See: Adjustments Calibrate the compass manually as follows: 1. Turn the ignition switch to the On position. If the compass/temperature data is not currently being displayed, momentarily depress and release the C/T push button to step through the display options until you have reached the compass/temperature display. 2. Depress and hold the RESET push button. Hold the push buttons down until "CAL" appears in the display. This takes about ten seconds. 3. Drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles in not less than 16 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: - A blank compass display indicates that vehicle degaussing (demagnetizing) is necessary. - If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure at least one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 8343 Compass: Service and Repair Demagnetizing Degaussing Tool #6029 A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 8344 11. Calibrate the compass, and adjust the compass variance. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Illumination Lamp > Page 8345 Compass: Service and Repair Module-Compass Temperature REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner 3. Remove the screws (1) that secure the Electronic Overhead Module (EOM) (4) to the overhead console housing (3). 4. Disconnect the overhead console wire harness connector from the EOM connector receptacle (2). 5. Remove the compass EOM (4) from the overhead console housing (3). INSTALLATION NOTE: If a new Electronic Overhead Module (EOM) has been installed, the compass will have to be calibrated and the variance set. 1. Position the Electronic Overhead Module (EOM) (4) onto the overhead console housing (3). 2. Reconnect the overhead console wire harness connector to the EOM connector receptacle (2). 3. Install the screws (1) that secure the EOM (4) to.the overhead console housing (3). Tighten the screws to 2 N.m (20 in. lbs.). 4. Install the overhead console (3) onto the headliner. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation Cruise Control Indicator Lamp: Description and Operation A cruise indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator is located on the left side of the cluster, to the left of the fuel gauge. The cruise indicator consists of a stencil-like cutout of the word CRUISE in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the cruise indicator is dimmable, which is adjusted along with the cluster illumination lamp using the panel lamps dimmer thumbwheel on the headlamp switch. The cruise indicator is serviced as a unit with the instrument cluster. The cruise indicator gives an indication to the vehicle operator when the speed control system is on, regardless of whether the speed control is engaged. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The cruise indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the cruise indicator for the following reasons: - Cruise Lamp-On Message - Each time the cluster receives a cruise lamp-on message from the PCM indicating the speed control system is on, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a cruise lamp-off message from the PCM or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cruise indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the speed control switches to determine the proper outputs to the speed control servo. The PCM then sends the proper cruise indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the cruise indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the speed control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the cruise indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 8354 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 8355 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation A door ajar indicator is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The door ajar indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Door(s) Ajar in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The door ajar indicator is serviced as a unit with the instrument cluster. The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and hard wired inputs received by the cluster from the door ajar switches located in each door latch unit. The door ajar indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the door ajar indicator for the following reasons: - Door Ajar Switch Input - Each time the cluster detects ground on any one of the door ajar switch sense circuits (door ajar switch closed = door is open or not completely latched) the door ajar indicator will be illuminated. The indicator remains illuminated until all of the door ajar switch sense inputs to the cluster are an open circuit (door ajar switch open = door fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the door ajar indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the door ajar switches to determine the status of the doors. For further diagnosis of the door ajar indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the door ajar switches and circuits, refer to the appropriate wiring information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro- Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Controller Area Network (CAN) data bus. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic message inputs or outputs used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8366 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8367 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8368 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8369 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8377 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8378 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8379 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8380 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8381 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8385 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8386 Module - Electronic Overhead (Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8387 Driver/Vehicle Information Display: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-49-2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8388 8w-49-3 (Gas) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8389 8w-49-4 (Diesel) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Page 8390 Driver/Vehicle Information Display: Description and Operation An overhead console (1) is available on this vehicle and includes the following components: - Front map/reading lamps (2) - A blue-green vacuum-fluorescent display screen (4) - if equipped with Compass Mini-Trip Computer - Universal transmitter (3) - if equipped - Electronic Overhead Module (EOM) The overhead console assembly is mounted by two snap clips and screws securing it to a molded plastic retainer bracket located above the headliner. The EOM is accessed by removing the overhead console from the bracket and pulling it away from the headliner. COMPASS DISPLAY NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. All the available overhead consoles on this model include Compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle at 5 to 8 kilometers-per-hour (3 to 5 miles-per hour), on level ground in a square shaped pattern. This will reorient the compass unit to its vehicle. The compass unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing procedure may be required to restore proper compass operation. TEMPERATURE DISPLAY All the available overhead consoles on this model include Temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. Displayed temperature reading stays in the temperature unit memory. When the ignition switch is turned to the On position, the temperature will display the memory temperature if the engine OFF time is less than 90 minutes. If the engine OFF time is more than 90 minutes, the temperature will display the actual temperature sensed by the ambient temperature sensor. The temperature display update interval varies with the vehicle speed. The temperature function is supported by an ambient temperature sensor. This sensor is mounted outside the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM). The FCM sends temperature status messages to the Cab Compartment Node (CCN) over the Controller Area Network (CAN) data bus circuit. The CCN then transfers the temperature information to the EOM for display on the vacuum-fluorescent display screen. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console Driver/Vehicle Information Display: Testing and Inspection Overhead Console NOTE: The temperature, fuel economy, distance to empty and trip odometer are calculated in the Cab Compartment Node (CCN) and transferred to the Electronic Overhead Module (EOM) for display. If the EOM and Vacuum Fluorescent Display (VFD) test OK testing of the CCN and Controller Area Network (CAN) data bus circuit may be necessary. Refer to the proper Diagnostic Procedures Information to test the CCN and CAN data bus circuit. If the problem with the overhead console is an inaccurate or scrambled display, refer to SELFDIAGNOSTIC TEST. See: Self-Diagnostic Test If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper Diagnostic Procedures Information to test for the correct dimming message inputs being received from the Cab Compartment Node (CCN) or Front Control Module (FCM) over the Controller Area Network (CAN) data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. 2. Inspect the Ignition Off Draw (IOD) fuse in the Totally Integrated Power Module (TIPM). If the IOD fuse is OK and in place, go to Step 3. If not OK, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If OK, go to Step 4. If not OK, Check for battery voltage at the appropriate B(+) fuse in the Totally Integrated Power Module (TIPM), repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If OK, go to Step 5. If not OK, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If OK, refer to SELF- DIAGNOSTIC TEST See: Self-Diagnostic Test for further diagnosis of the electronics module and the CAN data bus circuit. If not OK, repair the open ground circuit as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Overhead Console > Page 8393 Driver/Vehicle Information Display: Testing and Inspection Self-Diagnostic Test A self-diagnostic test is used to determine that the EOM is operating properly electrically. Initiate the self-diagnostic test as follows: NOTE: The compass mini-trip computer self - test can also be performed using a scan tool. Refer to Auto Self Test under the System Tests. 1. With the ignition switch in the Off position, simultaneously depress and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons depressed until the EOM enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EOM performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If module is equipped with the Universal Transmitter, the module also checks "Universal Transmitter Communication Test Status". 3. Following completion of these tests, the compass mini-trip computer will display one of two messages: "FAIL" or "PASS." Press RESET or STEP to exit and enter normal mode. Respond to these test results as follows: If no test result message is displayed, but compass mini-trip computer operation is still improper, the use of a scan tool and the proper Diagnostic Procedures Information are required for further diagnosis. - If the "FAIL" message is displayed, the EOM is inoperative and must be replaced. - If the "PASS" message is displayed, the EOM is OK, no faults are present. - If any VFD segment does not light during the display segment test, the EOM is inoperative and must be replaced. 4. If the first seven tests pass, the compass mini-trip computer shall verify that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EOM will automatically return to normal operation after sixty seconds. The EOM can also be returned to normal operation any time during the test by pressing the STEP, CT, RESET or US/M buttons. The required CAN bus messages are: Dimming message - VIN (Vehicle Identification Number) - Vehicle Speed message - Ignition On Time - Odometer - Trip Odometer - Vehicle Configuration (Model Year, Country and Vehicle Platform) - Fuel Economy - Distance To Empty - Ambient Air Temperature message NOTE: - Pressing the STEP or RESET switches during any portion of the testing procedure will cause the compass mini-trip computer to exit diagnostics and return to compass/temperature mode. - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading has blanked out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper Diagnostic Procedures as needed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement Driver/Vehicle Information Display: Service and Repair Module Lens Replacement 1. Remove the overhead console. 2. Remove the electronic overhead module from the overhead console. 3. Unsnap the lens from the module and replace lens as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 8396 Driver/Vehicle Information Display: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screw (3),located in the front of console near the windshield. 3. Using your fingertips, grasp the sides of the overhead console (2) and pull straight down evenly to disengage the two snap clips at the rear of the unit. 4. Lower the overhead console from the headliner far enough to access the wire harness connector (2). 5. Disconnect the roof wire harness connector (2) from the electronic overhead module. 6. Remove the overhead console from the vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Module Lens Replacement > Page 8397 1. Position the overhead console near the mounting location on the headliner. 2. Reconnect the roof wire harness connector (2) to the electronic overhead module. 3. Align the snap clips on the overhead console housing with their receptacles (3) in the overhead console bracket. 4. Push upward firmly and evenly on the sides of the overhead console housing over the snap clip locations until the snap clips are fully engaged with the receptacles in the overhead console bracket. 5. Install the overhead console retaining screw (3), located in the front of console near the windshield. 6. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation Electronic Throttle Control Indicator: Description and Operation An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional 5.7 liter gasoline engine, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system is ineffective or inoperative. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ETC indicator is illuminated for about six seconds. The entire bulb test is a function of the PCM. - ETC Lamp-On Message - Each time the cluster receives a lamp-on message from the PCM, the ETC indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about twelve seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator will be extinguished when the ignition switch is turned to the OFF position. - Communication Error - If the cluster receives no ETC lamp messages for three consecutive seconds, the ETC indicator is illuminated. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the ETC indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected an ETC system malfunction and/or that the ETC system is inoperative. The PCM will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, the instrument cluster and the PCM will each store a DTC. For proper diagnosis of the ETC system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ETC indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fog/Driving Lamp Indicator > Component Information > Description and Operation Fog/Driving Lamp Indicator: Description and Operation A fog lamp indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with optional fog lamps, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The fog lamp indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Front Fog Light in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The fog lamp indicator is serviced as a unit with the instrument cluster. The fog lamp indicator gives an indication to the vehicle operator whenever the optional fog lamps are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The fog lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the fog lamp indicator for the following reasons: - Fog Lamp-On Message - Each time the cluster receives a fog lamp-on message from the TIPM indicating the fog lamp circuit is energized, the fog lamp indicator will be illuminated. The indicator remains illuminated until the cluster receives a fog lamp-off message from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the fog lamp indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors a hard wired input from the headlamp switch to determine the selected fog lamp switch status. The instrument cluster then sends the proper fog lamp-on and lamp-off messages to the TIPM over the CAN data bus. The TIPM activates the fog lamp circuit then sends the proper fog lamp indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the fog lamp indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the fog lamp system, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the fog lamp indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Instruments - Overhead Average Fuel Economy Display Fuel Distance/Mileage Module: Technical Service Bulletins Instruments - Overhead Average Fuel Economy Display NUMBER: 08-020-06 GROUP: Electrical DATE: May 5, 2006 SUBJECT: Overhead Console Average Fuel Economy Display MODELS: 2006 (DR/DH) Ram Truck Discussion: On 2006 vehicles equipped with a Compass Mini Trip Computer (CMTC), the average fuel economy displayed after a reset has been changed. On previous models when the CMTC average fuel economy was reset by the customer, the new calculation was based on the fuel usage at the time the reset was activated. In this situation, if a customer was travelling up hill or accelerating, the display would show a very low average fuel economy and it could take considerable time for the display to reflect an accurate average fuel economy display. Conversely, if a customer was travelling down hill and was off the accelerator, the display would show very high fuel economy. On 2006 vehicles, the calculation has been changed to use the last displayed average fuel economy as a starting point for the calculation after a reset. The average fuel economy will then be adjusted from that point. If the display read 21.6 MPG at the time the reset was activated, the new display will start a 21.6 MPG and would change from that point depending on the current fuel usage. This was done to eliminate the extreme variations caused by very high or low fuel usage at the time of the reset. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: Customer Interest Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 8416 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set Fuel Filler Cap Warning Indicator: All Technical Service Bulletins Fuel System - MIL ON/DTC P0457 Set NUMBER: 14-001-06 GROUP: 14 - Fuel System DATE: January 21, 2006 SUBJECT: Loose Fuel Cap Message or MIL Illumination for Diagnostic Trouble Code P0457 EVAP System - Loose Fuel Cap MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (CS) Pacifica 2006 (DR/DH) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2006 (LX) 300/Magnum/Charger 2006 (PT) PT Cruiser 2007 (PM) Caliber 2006 (RS) Town & Country/Caravan/Voyager 2006 (TJ) Wrangler 2005 - 2006 (WK) Grand Cherokee 2006 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. NOTE: Do not replace the gas cap if only DTC P0457 - Evap System - Loose Fuel Cap is present. DISCUSSION: Starting with the introduction of 2005 model year vehicles a new diagnostic trouble code (DTC) P0457 - Evap System - Loose Fuel Cap was introduced. Also added to some vehicles was an instrument cluster message in the odometer display or message center (EVIC) that alerts the driver that the gas cap is loose. The PCM monitors the fuel level for a "significant" change in either direction and remembers that this has recently occurred. A loose fuel cap DTC, cluster message or message center message matures when the check for the EVAP system large leak condition fails after the fuel level change event. If a leak of greater than 0.090" is observed after a fuel level change, a loose cap diagnostic single trip failure is stored and the cluster message or message center message is displayed even though a DTC may not yet be present. DTC P0457 - Evap System - Loose Fuel Cap is stored and the MIL illuminated after 2 cold start failures of the large leak diagnostic checks following a fuel change event. Only the passing of one of the 3 EVAP system diagnostic routines large leak, small leak or loose gas cap) by the PCM will validate that the cap is no longer loose and turn off the MIL light or message. For 2007 model vehicles DTC P0457 - Evap System - Loose Fuel Cap will be stored and the MIL illuminated after 3 cold starts. To temporarily clear the gas cap loose message from the odometer or message center press the reset button on the odometer or message center while the message is being displayed. This clears the message for the current key cycle only. NOTE: The above works for all vehicles except, 2005 - 2006 Grand Cherokee or Commander. For these, the scantool must be used) To clear the gas cap loose message from the odometer or message center ensure the gas cap is tight and let the vehicle run the small leak diagnostic Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap Warning Indicator: > 14-001-06 > Jan > 06 > Fuel System - MIL ON/DTC P0457 Set > Page 8422 routine. The small leak diagnostic routine will pass a sealed system after an 8 hour soak and a negative 3° C change in fuel temperature from the last key cycle. NOTE: A heated garage may effect the small leak diagnostic routine. To clear the gas cap loose message from the odometer or message center and matured DTC (MIL light) diagnose and repair the leak and then erase DTC's with the DRBIII(R)/StarSCAN(TM) scantool NOTE: The DRBIII(R)/StarSCAN(TM) scantool may be used to reset the Loose Cap message. Select the PCM Reset function on StarSCAN(TM) (version 6.05_SPI or higher) or the Clear PCM Batt Disconnect function on DRB III(R). Disconnecting and reconnecting the battery will also clear the message. If a gas cap loose message is displayed or DTC P0457 - Evap System - Loose Fuel Cap is set without P0455 - Evap System Large Leak then ensure the gas cap it tight, no further service action is required. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8440 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8441 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8442 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8443 Fuel Gauge: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8444 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8445 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Diagram Information and Instructions > Page 8446 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Diagrams > Page 8447 Fuel Gauge: Description and Operation A fuel gauge is standard equipment on all instrument clusters. This gauge is located in the lower left quadrant of the instrument cluster, below the voltage gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from E (or Empty) to F (or Full). On SRT10 vehicles, a 1/2 designation is also imprinted under the center graduation on the scale. An International Control and Display Symbol icon for Fuel is located on the cluster overlay, directly below the right end of the gauge scale. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the Fuel icon on the gauge to provide the driver with a reminder as to the location of the fuel filler access. On vehicles equipped with a diesel engine, text that specifies DIESEL ONLY is located across the fuel gauge below the gauge scale, but above the hub of the gauge needle. On SRT10 vehicles, text that specifies premium only is located across the fuel gauge below the gauge scale, but above the hub of the gauge needle. On all vehicles except SRT10 the fuel gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale. On SRT10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned ON, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The fuel gauge is serviced as a unit with the instrument cluster. The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the fuel pump module in the fuel tank. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Fuel Level Sending Unit Input - The cluster provides a constant current source to the fuel level sending unit and monitors a return input on a fuel level sense circuit. The resistance through the fuel level sending unit increases as the fuel level falls and decreases as the fuel level rises causing changes in the sense input voltage. The cluster programming applies an algorithm to calculate the proper fuel gauge needle position based upon the fuel level sense input, then moves the gauge needle to the proper relative position on the gauge scale. This algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the cluster. - Less Than 15 Percent Tank Full Input - Each time the fuel level sense input to the cluster indicates the fuel tank is about 15 percent full or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the gauge needle is moved to about the one sixteenth graduation on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the fuel level sense input is greater than about 15 percent for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled off and then on again by the appropriate inputs from the fuel level sending unit. - Less Than Empty Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is less than the Empty gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is a short circuit. - More Than Full Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is more than the Full gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the fuel gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The cluster then sends the proper fuel level messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. For further diagnosis of the fuel gauge or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the fuel tank sending unit, the CAN data bus, or the electronic fuel level message outputs of the instrument cluster, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit Fuel Gauge Sender: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit > Page 8452 Fuel Gauge Sender: Locations Fuel Pump The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8455 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8456 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8457 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8458 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8459 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8460 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8461 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8462 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8463 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8464 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8465 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8466 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8467 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8468 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8469 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8470 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 8475 Fuel Gauge Sender: Description and Operation The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Diagrams > Page 8476 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 8482 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 8483 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation A low fuel indicator is standard equipment on all instrument clusters. This indicator is located on the left side of the instrument cluster, to the left of the fuel gauge. The low fuel indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Fuel in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input received by the cluster from the fuel level sending unit on the fuel pump module in the fuel tank. The low fuel indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the low fuel indicator is illuminated for about two seconds as a bulb test. - Less Than 15 Percent Tank Full Input - The cluster provides a constant current source to the fuel level sending unit and monitors a return input on a fuel level sense circuit. The resistance through the fuel level sending unit increases as the fuel level falls and decreases as the fuel level rises causing changes in the sense input voltage. Each time the fuel level sense input to the cluster indicates the fuel tank is about 15 percent or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the fuel gauge needle is moved to about the one-sixteenth graduation on the gauge scale, the low fuel indicator is illuminated, and a single chime tone is sounded. The low fuel indicator remains illuminated until the fuel level sense input indicates that the fuel tank full is greater than about 15 percent for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the low fuel indicator is cycled off and then on again by the appropriate inputs from the fuel level sending unit. - Less Than Empty Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is less than the Empty gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is a short circuit. - More Than Full Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is more than the Full gauge needle stop position, the gauge needle is moved to the low end of the gauge scale and the low fuel indicator is illuminated immediately. This input would indicate that the fuel level sense input to the cluster is an open circuit. - Actuator Test - Each time the cluster is put through the actuator test, the low fuel indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The cluster then sends the proper fuel level messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. For further diagnosis of the low fuel indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the fuel tank sending unit, the CAN data bus, or the electronic fuel level message outputs of the instrument cluster, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position, the SKREEM sends a TPM lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Lamp-On Message - Each time the cluster receives a TPM lamp-on message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a TPM lamp-off message from the SKREEM or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid TPM lamp-on or lamp-off message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the On position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper TPM lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is inoperative. For proper diagnosis of the SKREEM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the TPM indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Chrysler provides no information regarding a Maintenance Required Lamp/Indicator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or the Engine Control Module (ECM) on vehicles with a diesel engine has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM or ECM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the MIL for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the indicator is illuminated for about two seconds as a bulb test. The entire bulb test is a function of the PCM or ECM. - MIL Lamp-On Message - Each time the cluster receives a MIL lamp-on message from the PCM or ECM, the indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM or ECM message. For some DTC s, if a problem does not recur, the PCM or ECM will send a lamp-off message automatically. Other DTC s may require that a fault be repaired and the PCM or ECM be reset before a lamp-off message will be sent. - Communication Error - If the cluster receives no messages from the PCM or ECM for about ten seconds, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM or ECM. - Actuator Test - Each time the cluster is put through the actuator test, the MIL indicator will be turned on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM or ECM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM or ECM then sends the proper lamp-on or lamp-off messages to the instrument cluster. For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, refer to testing. If the instrument cluster turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. For proper diagnosis of the fuel and emissions systems, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the MIL, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation An odometer and trip odometer are standard equipment in all instrument clusters. The odometer, trip odometer, and engine hours information are displayed in a common electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The odometer, trip odometer, and engine hours information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/trip odometer switch button that extends through the lower edge of the cluster lens, just left of the tachometer. When the trip odometer information is displayed, the word "TRIP" is also illuminated in the lower right corner of the VFD in a blue-green color and at the same lighting level as the trip odometer information. The engine hours information replaces the selected odometer or trip odometer information whenever the ignition switch is in the On position and the engine is not running. The odometer, trip odometer, and engine hours information is stored in the instrument cluster memory. This information can be increased when the proper inputs are provided to the instrument cluster, but the information cannot be decreased. The odometer can display values up to 999,999 kilometers (999,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 999.9 kilometers (999.9 miles) before it rolls over to zero. Engine hours are displayed in the format, "hr9999". The cluster will accumulate values up to 9,999 hours before the display rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), while the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. The odometer also has a Rental Car mode, which will illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions. During daylight hours (exterior lamps are Off) the odometer VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are On), the VFD lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned On during daylight hours. The odometer/trip odometer VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. The engine hours give an indication of the cumulative engine-on time. This indicator is controlled by the instrument cluster circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) or Engine Control Module (ECM) over the Controller Area Network (CAN) data bus. The odometer, trip odometer and engine hours information is displayed by the instrument cluster odometer/trip odometer Vacuum Fluorescent Display (VFD). The VFD will display the odometer information whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions, and will display the last previously selected odometer or trip odometer information when the ignition switch is turned to the On or Start positions. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch button momentarily with the VFD illuminated will toggle the display between the odometer and trip odometer information. Each time the VFD is illuminated with the ignition switch in the On or Start positions, the display will automatically return to the last mode previously selected (odometer or trip odometer). - Engine Hours Display Toggling - When the trip odometer reset switch button is pressed and held for longer than about six seconds with the ignition switch in the On position and the engine speed message from the PCM is zero, the trip odometer information will be momentarily displayed, then the engine hours information will be displayed. The VFD must be displaying the odometer information when the trip odometer reset switch button is pressed in order to toggle to the engine hours display. The engine hours will remain displayed for about thirty seconds, until the engine speed message is greater than zero, or until the ignition switch is turned to the Off position, whichever occurs first. - Trip Odometer Reset - When the trip odometer reset switch button is pressed and held for longer than about two seconds with the ignition switch in the On or Start position, the trip odometer will be reset to 0.0 kilometers (miles). The VFD must be displaying the trip odometer information in order for the trip odometer information to be reset. - "GASCAP" Message Display - On vehicles manufactured with a United States country code, each time the cluster receives an electronic message from the PCM indicating a monitored leak in the evaporative emissions system, the cluster replaces the displayed odometer/trip odometer value with the text message "GASCAP". This message serves as a reminder to the vehicle operator to check that the gas cap is properly installed and tightened, but could also indicate another source of air leakage in the on-board evaporative and vapor recovery emissions systems. Unless the leak is corrected, this message will latch and remain displayed during the current and each subsequent ignition cycle until the trip odometer reset button is pressed and released momentarily, which will revert the display to the odometer/trip odometer information that was last displayed for the remainder of that ignition cycle. Once the source of a leak has been corrected, either momentarily pressing the trip odometer reset button or cycling the ignition switch will unlatch the message and return the odometer/ trip odometer to normal operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 8502 - Communication Error - If the cluster fails to receive a distance message during normal operation, it will hold and display the last data received until the ignition switch is turned to the Off position. If the cluster does not receive a distance message within one second after the ignition switch is turned to the On position, it will display the last distance message stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD will display "Error". - Actuator Test - Each time the cluster is put through the actuator test, the odometer VFD will display all of its segments simultaneously, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the vehicle speed pulse information received from the Vehicle Speed Sensor (VSS) or the Controller Anti-lock Brake (CAB) and engine speed pulse information received from the crankshaft position sensor, then sends the proper distance and engine speed messages to the instrument cluster. For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions, refer to testing. For proper diagnosis of the VSS, the crankshaft position sensor, the CAB, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the odometer/trip odometer, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair Chrysler provides no information regarding a Oil Change Reminder Lamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation An oil pressure gauge is standard equipment on all instrument clusters. This gauge is located in the upper right quadrant of the instrument cluster, above the coolant temperature gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT10. On SRT10 models the scale reads from "0" kPa to "700" kPa in markets where a metric instrument cluster is specified, or from 0 psi to 100 psi in all other markets. On vehicles with a diesel engine the scale reads from "0" kPa to "760" kPa in markets where a metric instrument cluster is specified, or from "0" psi to "110" psi in all other markets. An International Control and Display Symbol icon for "Engine Oil" is located on the cluster overlay, directly below the left end of the gauge scale. On all models except SRT10 the oil pressure gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale. On SRT10 the gauge graphics are black against a silver field except for a single red zone at the low end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The oil pressure gauge is serviced as a unit with the instrument cluster. The oil pressure gauge gives an indication to the vehicle operator of the engine oil pressure. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The oil pressure gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Oil Pressure Message - The instrument cluster circuitry restricts the oil pressure gauge needle operation in order to provide readings that are consistent with customer expectations. For all models except SRT10, each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster holds the gauge needle at a point near the middle increment within the normal range on the gauge scale. For SRT10 models, each time the cluster receives a message from the PCM indicating the engine oil pressure is above about 41 kPa (6 psi) the cluster moves the gauge needle in a linear fashion to the proper relative pressure position of the gauge scale. - Engine Oil Pressure Low Message - Each time the cluster receives three consecutive bus messages from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to the red graduation (except SRT10) or to the red zone (SRT10) at the far left end of the gauge scale, the check gauges indicator is illuminated, and a single chime tone is generated. The gauge needle remains at the left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine oil pressure is above about 41 kPa (6 psi), or until the ignition switch is turned to the Off position, whichever occurs first. The cluster will only turn the check gauges indicator on in response to an engine oil pressure low message if the engine speed message is greater than zero. - Communication Error - If the cluster fails to receive an engine oil pressure message, it will hold the gauge needle at the last indication for about ten seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After ten seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the oil pressure gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. On vehicles with a diesel engine, the ECM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM or ECM then sends the proper engine oil pressure messages to the instrument cluster. For further diagnosis of the oil pressure gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a low oil pressure gauge reading, it may indicate that the engine or the engine oiling system requires service. For proper diagnosis of the engine oil pressure sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the oil pressure gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Right And Front Engine (5.7L) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8514 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8515 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8516 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8517 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8518 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8519 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8520 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8521 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8522 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8523 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8524 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8525 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8526 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8527 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Oil Pressure Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Switch - Oil Pressure (Except SRT) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Customer Interest for Outside Temperature Display: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings Outside Temperature Display: Customer Interest Instruments - Incorrect Outside Temperature Readings NUMBER: 08-026-06 REV. A GROUP: Electrical DATE: October 25, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-026-06, DATED JUNE 02, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Overhead Console Temperature Reading Inaccurate Or Dome Lamp Turns Off Too Soon OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node (CCN) with new software. MODELS: 2006 (DRIDHID1) Ram Truck NOTE: This bulletin applies to vehicles built on or before May 30, 2006 (MDH 0530XX). SYMPTOM/CONDITION: The vehicle operator may notice that if a vehicle door is left open for longer than 20 seconds the illuminated interior (dome) lamps will turn off. The vehicle operator may describe that the ambient temperature first displayed in the overhead console is not accurate (displays -40°C or -40°F), when the ignition switch is turned to the "On" position, then slowly updates to the outside ambient temperature as the vehicle is driven. NOTE: DO NOT reprogram the CCN if the overhead displayed temperature stays at the -40°C (-40°F) reading after driving the vehicle for MORE THAN 3 minutes and at speeds greater than 32 Km/h (20 mph). Check the system for an open circuit condition. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Customer Interest for Outside Temperature Display: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 8543 REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash CCN" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the appropriate calibration then select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the CCN update is complete, select "OK". I. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > Customer Interest for Outside Temperature Display: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 8544 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Outside Temperature Display: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings Outside Temperature Display: All Technical Service Bulletins Instruments - Incorrect Outside Temperature Readings NUMBER: 08-026-06 REV. A GROUP: Electrical DATE: October 25, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-026-06, DATED JUNE 02, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) UPDATE CD 6.05 WAS THE LAST CD TO CONTAIN FLASH FILES. SUBJECT: Flash: Overhead Console Temperature Reading Inaccurate Or Dome Lamp Turns Off Too Soon OVERVIEW: This bulletin involves selectively erasing and reprogramming the Cabin Compartment Node (CCN) with new software. MODELS: 2006 (DRIDHID1) Ram Truck NOTE: This bulletin applies to vehicles built on or before May 30, 2006 (MDH 0530XX). SYMPTOM/CONDITION: The vehicle operator may notice that if a vehicle door is left open for longer than 20 seconds the illuminated interior (dome) lamps will turn off. The vehicle operator may describe that the ambient temperature first displayed in the overhead console is not accurate (displays -40°C or -40°F), when the ignition switch is turned to the "On" position, then slowly updates to the outside ambient temperature as the vehicle is driven. NOTE: DO NOT reprogram the CCN if the overhead displayed temperature stays at the -40°C (-40°F) reading after driving the vehicle for MORE THAN 3 minutes and at speeds greater than 32 Km/h (20 mph). Check the system for an open circuit condition. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Outside Temperature Display: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 8550 REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: Before performing this Repair Procedure, the operating software in the StarSCAN(R); must be programmed with software release level 7.01 SPI or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN® for the dealer's network refer to either: "DealerCONNECT > Service > StarSCAN and StarMOBILE tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: The Repair Procedure (CCN flash) currently can not be performed using the StarMOBILE(TM) in its STANDALONE mode. Use the StarSCAN(TM) to perform the Repair Procedure, or use the StarMOBILE(TM) in its CONNECTED mode to perform the Repair Procedure. NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404 StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Retrieve the old CCN part number. Using the StarSCAN(R) at the "Home" screen: a. Select "ECU View" b. Touch the screen to highlight the CCN in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash CCN" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Highlight the appropriate calibration then select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the CCN update is complete, select "OK". I. Verify the part number at the top of the "Flash CCN" screen has updated to the new part number. NOTE: Due to the CCN programming procedure, a DTC may be set in other modules (PCM, TCM, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Outside Temperature Display: > 08-026-06A > Oct > 06 > Instruments - Incorrect Outside Temperature Readings > Page 8551 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator Overdrive Indicator Lamp: Description and Operation Overdrive Off Indicator An overdrive off indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The overdrive off indicator consists of a stencil-like cutout of the text O/D OFF in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the overdrive off indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The overdrive off indicator is serviced as a unit with the instrument cluster. The overdrive off indicator gives an indication to the vehicle operator when the overdrive off feature has been selected using the tow/haul switch, disabling the electronically controlled overdrive feature of the automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The overdrive off indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the overdrive off indicator for the following reasons: - Overdrive Off Lamp-On Message - Each time the cluster receives an overdrive off lamp-on message from the PCM indicating that the overdrive off feature has been selected, the overdrive off indicator will be illuminated. The indicator remains illuminated until the cluster receives an overdrive off lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the overdrive off indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper overdrive off lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the overdrive off indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the overdrive off indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Overdrive Off Indicator > Page 8556 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator A tow/haul indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional overdrive automatic transmission, this indicator is electronically disabled. This indicator is located on the right side of the instrument cluster, to the right of the coolant temperature gauge. The tow/haul indicator consists of a stencil-like cutout of the text "TOW/HAUL" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned On, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. The tow/haul indicator gives an indication to the vehicle operator when the tow/haul feature has been selected using the tow/haul switch, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the tow/haul indicator for the following reasons: - Tow/Haul Lamp-On Message - Each time the cluster receives a tow/haul lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the tow/haul indicator will be illuminated. The indicator remains illuminated until the cluster receives a tow/haul lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. Actuator Test - Each time the cluster is put through the actuator test, the tow/haul indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper tow/haul lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the transmission control system, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tow/haul indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation Parking Brake Warning Lamp: Description and Operation A brake indicator is standard equipment on all instrument clusters. This indicator is located near the lower edge of the instrument cluster, between the tachometer and the speedometer. The brake indicator consists of a stencil-like cutout of the word BRAKE and the International Control and Display Symbol icon for Brake Failure in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the text and icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the brake indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Lamp-On Message - Each time the cluster receives a lamp-on message from the CAB, the brake indicator will be illuminated. The CAB can also send brake lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the instrument cluster is put through the actuator test, the brake indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hard wired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off messages to the instrument cluster. If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction and/or that the ABS system has become inoperative. The CAB will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, refer to testing. The park brake switch input to the instrument cluster can be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information. For proper diagnosis of the brake fluid level switch, the ABS, the CAB, the CAN data bus, or the electronic message inputs to the instrument cluster that control the brake indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 8560 Parking Brake Warning Lamp: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. The hard wired park brake switch input to the EMIC may be diagnosed and tested using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus, or the electronic message inputs also used by the EMIC to provide brake indicator operation. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAB, the CAN data bus, and the electronic message inputs for the brake indicator operation requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8564 Switch - Parking Brake Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8565 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Refer to appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8566 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an inoperative park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 8567 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Technical Service Bulletins > Instruments - Overhead Average Fuel Economy Display Fuel Distance/Mileage Module: Technical Service Bulletins Instruments - Overhead Average Fuel Economy Display NUMBER: 08-020-06 GROUP: Electrical DATE: May 5, 2006 SUBJECT: Overhead Console Average Fuel Economy Display MODELS: 2006 (DR/DH) Ram Truck Discussion: On 2006 vehicles equipped with a Compass Mini Trip Computer (CMTC), the average fuel economy displayed after a reset has been changed. On previous models when the CMTC average fuel economy was reset by the customer, the new calculation was based on the fuel usage at the time the reset was activated. In this situation, if a customer was travelling up hill or accelerating, the display would show a very low average fuel economy and it could take considerable time for the display to reflect an accurate average fuel economy display. Conversely, if a customer was travelling down hill and was off the accelerator, the display would show very high fuel economy. On 2006 vehicles, the calculation has been changed to use the last displayed average fuel economy as a starting point for the calculation after a reset. The average fuel economy will then be adjusted from that point. If the display read 21.6 MPG at the time the reset was activated, the new display will start a 21.6 MPG and would change from that point depending on the current fuel usage. This was done to eliminate the extreme variations caused by very high or low fuel usage at the time of the reset. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation A seatbelt indicator is standard equipment on all instrument clusters. The seatbelt indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired input from the seatbelt switch in the driver side front seatbelt buckle through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or beltminder feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the seatbelt indicator for the following reasons: - Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator will be illuminated as a seatbelt reminder for about six seconds, or until the ignition switch is turned to the Off position, whichever occurs first. This reminder function will occur regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. In addition, if the driver side front seat belt remains unbuckled about sixty seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 8 kilometers-per-hour (5 miles-per-hour), the seatbelt indicator will begin to cycle between flashing on and off for three seconds, then lighting solid for two seconds. The seatbelt indicator will continue to cycle between flashing and solid illumination for thirteen complete cycles, until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the Start or On positions, the indicator will be illuminated. The seatbelt indicator remains illuminated until the seat belt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch is turned to the Off position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it will send a message indicating the fault to the Occupant Restraint Controller (ORC), then flash the seatbelt indicator on and off. The cluster will continue to flash the seatbelt indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seat belt indicator driver input to the instrument cluster. The seatbelt switch input to the instrument cluster circuitry may be diagnosed using conventional diagnostic tools and methods. Refer to the appropriate wiring information. For further diagnosis of the seatbelt indicator or the instrument cluster circuitry that controls the LED, refer to testing. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming Seat Belt Reminder Lamp: Service and Repair Enhanced Seatbelt Reminder Programming The seatbelt indicator also includes a programmable enhanced seatbelt reminder or beltminder feature that is enabled when the vehicle is shipped from the factory. This beltminder feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The beltminder feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Service and Repair > Enhanced Seatbelt Reminder Programming > Page 8578 Seat Belt Reminder Lamp: Service and Repair Customer Programming Sequence NOTE: The following sequence of events must occur within sixty (60) seconds of the ignition switch being placed in the On position in order for the programming to be completed successfully. 1. With all doors closed and the ignition switch in any position except On or Start, buckle the driver side front seat belt. 2. Turn the ignition switch to the On position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except On or Start to toggle the beltminder feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro- Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Controller Area Network (CAN) data bus. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic message inputs or outputs used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit Fuel Gauge Sender: Locations Fuel Level Sending Unit The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Fuel Level Sending Unit > Page 8587 Fuel Gauge Sender: Locations Fuel Pump The electric fuel pump is located inside of the fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8590 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8591 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8592 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8593 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8594 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8595 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8596 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8597 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8598 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8599 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8600 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8601 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8602 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8603 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8604 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8605 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8606 Fuel Gauge Sender: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8607 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8608 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 8609 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 8610 Fuel Gauge Sender: Description and Operation The fuel tank module is installed in the top of the fuel tank. The fuel tank module contains the following components: - An electric fuel transfer (lift) pump - Fuel reservoir - A separate in-tank fuel filter - Fuel gauge sending unit (fuel level sensor) - Fuel supply line connection - A special lockring to retain module to fuel tank - Fuel return line connection Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Page 8611 Fuel Gauge Sender: Service and Repair REMOVAL The fuel level sending unit (fuel level sensor) and float assembly (7) is located on the side of the fuel pump module. 1. Remove fuel pump module from fuel tank. 2. Disconnect 4 wire electrical connector (3) from fuel pump module. Separate necessary sending unit wiring from connector using terminal pick/removal tool. Refer to Special Tools for tool part numbers. 3. To remove sending unit from pump module, lift on plastic locking tab while sliding sending unit tracks. INSTALLATION 1. Connect necessary wiring into electrical connectors. Connect 4 wire electrical connector to pump module. 2. Position sending unit to pump module. Slide and snap into place. 3. Install fuel pump module. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Description and Operation Key Reminder Switch: Description and Operation KEY-IN IGNITION SWITCH DESCRIPTION The key-in ignition switch is integral to the ignition switch, which is mounted on the left side of the steering column. It closes a path to ground for the Central Timer Module (CTM) when the ignition key is inserted in the ignition key cylinder and the driver door ajar switch is closed (driver door is open). The key-in ignition switch opens the ground path when the key is removed from the ignition key cylinder. The ground path is also opened when the driver door ajar switch is open (driver door is closed). The key-in ignition switch cannot be repaired and, if faulty or damaged, the entire ignition switch must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8618 Switch - Parking Brake Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8619 Parking Brake Warning Switch: Description and Operation The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the EMIC processing of the park brake switch sense input requires the use of a diagnostic scan tool. Refer to appropriate diagnostic information. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8620 Parking Brake Warning Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. NOTE: If the brake indicator stays on with the ignition switch in the On position and the park brake released, or comes on while driving, the brake system must be diagnosed and repaired prior to performing the following tests. If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an inoperative park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OK 1. Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to Step 2. If not OK, replace the inoperative park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 8621 Parking Brake Warning Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. INSTALLATION 1. Reach under the left end of the instrument panel to position park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 N.m (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. 5. Turn the ignition switch to the On position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation A speedometer is standard equipment on all instrument clusters. The speedometer is located next to the tachometer, just to the right of center in the instrument cluster. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face. For all models except SRT10 the speedometer reads left-to-right either from "0" to "120" mph, or from "0" to "200" km/h, depending upon the market for which the vehicle is manufactured. On SRT10 the speedometer reads left-to right either from "0" to "160" mph, or from "0" to "280" km/h , depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay just below the hub of the speedometer needle abbreviates the unit of measure for the primary scale (i.e.: MPH or km/h), followed by the unit of measure for the secondary scale. The speedometer graphics for all models except SRT10 are black (primary scale) and blue (secondary scale) against a white field. On SRT10 the gauge graphics are black (primary scale) and gray (secondary scale) against a silver field. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the blue graphics appear light blue. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The speedometer is serviced as a unit with the instrument cluster. The speedometer gives an indication to the vehicle operator of the vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Vehicle Speed Message - Each time the cluster receives a vehicle speed message from the PCM it will calculate the correct vehicle speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster will receive a new vehicle speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be positioned at the relative vehicle speed position on the gauge scale until the vehicle stops moving, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive a speedometer message, it will hold the gauge needle at the last indication for about three seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After three seconds, the gauge needle will return to the left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the speedometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the Vehicle Speed Sensor (VSS) or electronic wheel speed messages from the Controller Anti-lock Brake (CAB) to determine the vehicle road speed. The PCM then sends the proper vehicle speed messages to the instrument cluster. For further diagnosis of the speedometer or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the VSS, the CAB, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the speedometer, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation A tachometer is standard equipment on all instrument clusters. The tachometer is located to the left of the speedometer, just to the left of center in the instrument cluster. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face. On all models except SRT10, the tachometer reads left-to-right from "0" to "7" for gasoline engines, or from "0" to "5" for diesel engines. On SRT10 models, the tachometer reads left-to-right from "0" to "8". On all models except SRT10, the text "RPM X 1000" is imprinted on the cluster overlay directly below the hub of the tachometer needle. On SRT10 models the text "X 1000 RPM" is imprinted on the cluster overlay directly below the hub of the tachometer needle. This text identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. On all models except SRT10 the tachometer graphics are black against a white field. On SRT10 the tachometer graphics are black against a silver field. SRT10 also has a red zone that is designated by a red dot matrix on the dial face that radiates wedge-like from the hub of the gauge needle to cover from the "6" to the "8" area at the high end of the scale, and short red arced lines extend between the major graduations within that area of the scale. The SRT10 tachometer also includes the text, SRT 10 directly above the hub of the tachometer needle. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The tachometer is serviced as a unit with the instrument cluster. The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Speed Message - Each time the cluster receives an engine speed message from the PCM or ECM it will calculate the correct engine speed reading and position the gauge needle at that relative engine speed position on the gauge scale. The cluster will receive a new engine speed message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle will continually be repositioned at the relative engine speed position on the gauge scale until the engine stops running, or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine speed message, it will hold the gauge needle at the last indication for about three seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After three seconds, the gauge needle will return to the left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the tachometer needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the crankshaft position sensor to determine the engine speed. On vehicles with a diesel engine, the ECM continually monitors the engine speed sensor to determine the engine speed. The PCM or ECM then sends the proper engine speed messages to the instrument cluster. For further diagnosis of the tachometer or the instrument cluster circuitry that controls the gauge, refer to testing. For proper diagnosis of the crankshaft position sensor, the engine speed sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the tachometer, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation An engine coolant temperature gauge is standard equipment on all instrument clusters. The engine coolant temperature gauge is located in the lower right quadrant of the instrument cluster, below the oil pressure gauge. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from C (or Cold) to H (or Hot) for gasoline engines except SRT10. On SRT10 models, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 260° F in all other markets. On vehicles with a diesel engine, the scale reads from 60° C to 120° C in markets where a metric instrument cluster is specified, or from 140° F to 245° F in all other markets. An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the left end of the gauge scale. On all vehicles except SRT10 the engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale. On SRT10 the gauge graphics are black against silver field except for a single red zone at the high end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black gauge graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by replaceable incandescent bulb and holder units located on the instrument cluster electronic circuit board. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is between the low end of normal [about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines] and the high end of normal [about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines], the gauge needle is moved to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine coolant temperature is below the low end of normal [about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines], the gauge needle is held at the graduation on the far left end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM or ECM indicating that the engine temperature is above about 54° C (130° F) for gasoline engines except SRT10, or about 60° C (140° F) for SRT10 and diesel engines, or until the ignition switch is turned to the Off position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the engine coolant temperature is above about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, the gauge needle is moved to the red increment or zone at the far right end of gauge scale, the check gauges indicator is illuminated, and a single chime tone is sounded. The gauge needle remains at the high end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating that the engine temperature is below about 122° C (252° F) for gasoline engines, or about 116° C (240° F) for diesel engines, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the check gauges indicator is cycled off and then on again by the appropriate engine temperature messages from the PCM or ECM. - Communication Error - If the cluster fails to receive an engine temperature message, it will hold the gauge needle at the last indication for about 10 seconds, or until the ignition switch is turned to the OFF position, whichever occurs first. After 10 seconds, the cluster will move the gauge needle to the low end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the engine coolant temperature gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM or ECM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM or ECM then sends the proper engine coolant temperature messages to the instrument cluster. For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. For proper diagnosis of the engine coolant temperature sensor, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the engine coolant temperature gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Indicator - A/T > Component Information > Description and Operation Temperature Warning Indicator - A/T: Description and Operation A transmission over-temperature indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The transmission over-temperature indicator is serviced as a unit with the instrument cluster. The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the transmission over-temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Lamp-On Message - Each time the cluster receives a trans over-temp lamp-on message from the PCM indicating that the transmission fluid temperature is 135° C (275° F) or higher, the indicator will be illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a trans over-temp lamp-off message from the PCM, or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the transmission over-temperature indicator is cycled off and then on again by the appropriate trans over-temp messages from the PCM. - Actuator Test - Each time the cluster is put through the actuator test, the transmission over-temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper trans over-temp lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the transmission over-temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission and/or the transmission cooling system are being overloaded or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, refer to testing. For proper diagnosis of the transmission temperature sensor, the PCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the transmission over-temperature indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation Low Tire Pressure Indicator: Description and Operation A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provide a path to ground by the instrument cluster transistor. The instrument cluster will turn on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position, the SKREEM sends a TPM lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Lamp-On Message - Each time the cluster receives a TPM lamp-on message from the SKREEM, the TPM indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a TPM lamp-off message from the SKREEM or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid TPM lamp-on or lamp-off message is received from the SKREEM. - Actuator Test - Each time the cluster is put through the actuator test, the TPM indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the On position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or too low. The SKREEM then sends the proper TPM lamp-on or lamp-off messages to the instrument cluster. If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is inoperative. For proper diagnosis of the SKREEM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the TPM indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator Traction Control Indicator Lamp: Description and Operation Electronic Stability Program/Brake Assist System Indicator An ESP/BAS indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional Electronic Stability Program (ESP)/Brake Assist System (BAS), this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. The ESP/BAS indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/ Brake Assist System (BAS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the ESP/BAS indicator is illuminated for about four seconds as a bulb test. - ESP/BAS Lamp-On Message - Each time the cluster receives an ESP/BAS lamp-on message from the CAB or the TIPM, the ESP/BAS indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the CAB or TIPM message. The indicator remains illuminated until the cluster receives an ESP/BAS lamp-off message from the CAB or TIPM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the ESP/BAS indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and TIPM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or TIPM then sends the proper ESP/BAS lamp-on and lamp-off messages to the instrument cluster. For proper diagnosis of the ESP/ BAS system, the CAB, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the ESP/BAS indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > Electronic Stability Program/Brake Assist System Indicator > Page 8642 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator TRACTION CONTROL INDICATOR A traction control indicator is only found in the instrument clusters for vehicles equipped with a gasoline engine. However, on vehicles not equipped with the optional Traction Control System (TCS), this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The traction control indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Stability - Anti-Spin" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The traction control indicator is serviced as a unit with the instrument cluster. The traction control indicator gives an indication to the vehicle operator when the electronic Traction Control System (TCS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The traction control indicator is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The indicator only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the traction control indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the traction control indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Traction Control Lamp-On Message - Each time the cluster receives a traction control lamp-on message from the CAB indicating that the TCS has been activated, the traction control indicator will be illuminated. The indicator remains illuminated until the cluster receives a traction control lamp-off message from the CAB, or until the ignition switch is turned to the Off position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the traction control indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB continually monitors the traction control switch to determine the proper outputs to the components of the Antilock Brake System (ABS). The CAB then sends the proper traction control lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the traction control indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the traction control switch, the ABS, the CAB, the CAN data bus, or the electronic message inputs to the instrument cluster that control the traction control indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T > Component Information > Description and Operation Transmission Mode Indicator - A/T: Description and Operation An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. However, on vehicles not equipped with an optional automatic transmission, this indicator is electronically disabled. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the speedometer dial face of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a Parade mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the instrument cluster. The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming. The cluster circuitry automatically configures itself for the proper transmission type and model based upon the hard wired transmission range sensor mux circuit input to the cluster. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch is turned to the OFF position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission model that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry configures the gear selector indicator VFD based upon the following inputs from the transmission range sensor: - Open Circuit - If the cluster is configured for an automatic transmission and the transmission range sensor mux circuit is open, the cluster circuitry controls the gear selector indicator display based upon electronic messages received from the electronic Transmission Control Module ( TCM) over the Controller Area Network (CAN) data bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Resolved Circuit - If the transmission range sensor mux circuit is resolved, the cluster circuitry controls the gear selector indicator display based upon the resistance value of the hard wired input from the transmission range sensor. If the cluster is configured for an automatic transmission with a transmission range sensor input and detects a short to ground or an open in the transmission range sensor mux input, the instrument cluster circuitry will not display any gear selector position in the VFD. The VFD display for the short-to-ground and open circuit conditions will continue until the condition is resolved or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the odometer/trip odometer VFD will display all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. On vehicles with a TCM, the TCM continually monitors the Transmission Range Sensor (TRS), then sends the proper gear selector indicator position messages to the instrument cluster. On vehicles without a TCM, the instrument cluster continually monitors the hard wired transmission range sensor multiplexed input. For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, refer to testing. For further diagnosis of the TRS on vehicles without a TCM, refer to Transmission and Drivetrain/Automatic Transmission/ Transaxle. On vehicles with a TCM, for proper diagnosis of the TRS, the TCM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the gear selector indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation A voltage gauge is standard equipment on all instrument clusters. This gauge is located in the upper left quadrant of the instrument cluster, above the fuel gauge. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree scale on the cluster overlay that reads left-to-right from "L" (or Low) to "H" (or High) for gasoline engines except SRT10. On SRT10 models the scale reads from "10" to "18" volts. On vehicles with a diesel engine, the scale reads from "8" to "18" volts. An International Control and Display Symbol icon for "Battery Charging Condition" is located on the cluster overlay, directly below the right end of the gauge scale. On all models except SRT10 the voltage gauge graphics are black against a white field except for a single red graduation at each end of the gauge scale. On SRT10 the gauge graphics are black against a silver field except for a single red graduation at the left end of the gauge scale and two red graduations at the right end of the gauge scale. In either case, the gauge graphics are clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster illumination lighting with the exterior lamps turned On, the black graphics appear blue-green and the red graphics still appear red. The gauge needle has internal optical illumination. Gauge illumination is provided by a replaceable incandescent bulb and holder unit located on the instrument cluster electronic circuit board. The voltage gauge is serviced as a unit with the instrument cluster. The voltage gauge gives an indication to the vehicle operator of the electrical system voltage. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) on vehicles equipped with a gasoline engine, or from the Engine Control Module (ECM) on vehicles equipped with a diesel engine over the Controller Area Network (CAN) data bus. The voltage gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the On or Start positions. The cluster is programmed to move the gauge needle back to the left end of the scale after the ignition switch is turned to the Off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: System Voltage Message - Each time the cluster receives a system voltage message from the PCM or ECM indicating the system voltage is between about 9.5 volts and about 15 volts, the gauge needle is moved to the relative voltage position on the gauge scale. - System Voltage Low (Charge Fail) Message - Each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is less than about 9 volts (charge fail condition) or that the battery temperature sensor input is an open circuit, the gauge needle is moved to the graduation on the far left end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the far left end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a single message from the PCM or ECM indicating the electrical system voltage is greater than about 9.5 volts (but less than about 15.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. On vehicles equipped with the optional diesel engine, the ECM is programmed to restrict the voltage gauge needle to a position above the graduation on the far left end of the gauge scale and suppress the check engine indicator operation until after the engine intake manifold air heater has completed a pre-heat or post-heat cycle. - System Voltage High Message - On all models except SRT10, each time the cluster receives three consecutive messages from the PCM or ECM indicating the electrical system voltage is greater than about 15.5 volts, the gauge needle is moved to the graduation on the far right end of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at the right end of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM or ECM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. On SRT10, each time the cluster receives three consecutive messages from the PCM indicating the electrical system voltage is greater than about 15.5 volts, the gauge needle is moved to the 16 volt graduation of the gauge scale and the check gauges indicator is illuminated. The gauge needle remains at or above the 16 volt graduation of the gauge scale and the check gauges indicator remains illuminated until the cluster receives a message from the PCM indicating the electrical system voltage is less than about 15.0 volts (but greater than about 9.5 volts), or until the ignition switch is turned to the Off position, whichever occurs first. - Communication Error - If the cluster fails to receive a system voltage message, it will hold the gauge needle at the last indication for about three seconds, or until the ignition switch is turned to the Off position, whichever occurs first. After three seconds, the cluster will move the gauge needle to the far left end of the gauge scale. - Actuator Test - Each time the cluster is put through the actuator test, the voltage gauge needle will be swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. On vehicles with a gasoline engine, the PCM continually monitors the system voltage to control the generator output. On vehicles with a diesel engine, the ECM continually monitors the system voltage to control the generator output. The PCM or ECM then sends the proper system voltage messages to the instrument cluster. For further diagnosis of the voltage gauge or the instrument cluster circuitry that controls the gauge, refer to testing. If the instrument cluster turns on the check gauges indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. For proper diagnosis of the charging system, the PCM, the ECM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the voltage gauge, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8655 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8656 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Switch - Backup Lamp (M/T 5.7L HD/Diesel M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 8676 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if inoperative or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams > Page 8677 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the inoperative backup lamp switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Bulb - Pick-Up Brake Light Bulb: Service and Repair Bulb - Pick-Up NOTE: The rear lamp unit contains three bulbs: park/turn signal, park/brake/side marker, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. 3. Remove the four screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp unit. 5. Pull the base of the backup (1), park/brake/side marker (2) or park/turn signal (3) lamp bulb straight out of the appropriate socket in the socket plate (5). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the backup (1), park/brake/side marker (2) or park/turn signal (3) lamp bulb with the appropriate socket in the socket plate (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Bulb - Pick-Up > Page 8683 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber sealing washer (4) is properly installed and in good condition around the base of each bulb on the socket plate. 4. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 5. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 6. Install and tighten the four screws (3) that secure the socket plate to the housing. Tighten the screws to 1 N.m (12 in. lbs.). 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Bulb - Pick-Up > Page 8684 Brake Light Bulb: Service and Repair Bulb - Cab and Chassis NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn signal/brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the backup lamp bulb (4), or the park/turn signal/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 N.m (20 in. lbs.). 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8688 Switch - Stop Lamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8689 Brake Light Switch: Description and Operation The brake lamp switch (2) is a three circuit, springloaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, inoperative, or removed from its mounting position for any reason, it must be replaced with a new unit. The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned On and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch is diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8690 Brake Light Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the inoperative brake lamp switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8691 Brake Light Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. 6. Discard the removed brake lamp switch. INSTALLATION 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8692 seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams Lamp - High Mounted Stop/Cargo Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 8696 Cargo Lamp: Description and Operation A cargo lamp indicator is standard equipment on all instrument clusters. The cargo lamp indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The cargo lamp indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Working Light in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The cargo lamp indicator is serviced as a unit with the instrument cluster. The cargo lamp indicator gives an indication to the vehicle operator when the exterior cargo lamp is illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, a hard wired multiplex input received by the cluster from the cargo lamp switch on the headlamp dimmer switch mux circuit, and electronic unlock request messages received from the optional Sentry Key REmote Entry Module (SKREEM) module. The cargo lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the cargo lamp indicator for the following reasons: - Cargo Lamp-On Input - Each time the cluster detects a cargo lamp-on input from the headlamp switch on the headlamp dimmer switch mux circuit, the cargo lamp and the cargo lamp indicator will be illuminated. The cargo lamp and indicator remain illuminated until the cluster receives a cargo lamp-off input from the headlamp switch, until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch is turned to the OFF position, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the cargo lamp indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the headlamp dimmer switch circuit to determine the proper interior lamps features and panel lamps illumination levels to provide. The cluster then energizes and de-energizes a low side driver circuit to control the exterior cargo lamp. Each time the instrument cluster energizes the cargo lamp driver and the ignition switch is in the ON or START positions, the cluster also turns on the cargo lamp indicator. For further diagnosis of the cargo lamp indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the cargo lamp or the headlamp switch inputs to the instrument cluster that control the cargo lamp indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Diagrams > Page 8697 Cargo Lamp: Service and Repair NOTE: The Center High Mounted Stop Lamp (CHMSL) houses three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets on the back of the lamp. 4. Firmly grasp either outboard socket (3) on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with either keyed outboard opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 N.m (20 in. lbs.). 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair Center Mounted Brake Lamp Bulb: Service and Repair NOTE: The Center High Mounted Stop Lamp (CHMSL) houses three bulbs. The center bulb is the CHMSL bulb and illuminates through a red lens, while the two outboard bulbs are for the cargo lamps and illuminate through clear lenses. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the CHMSL to the rear cab roof header panel. 3. Pull the CHMSL lens and housing (1) away from the header panel far enough to access the lamp wiring and bulb sockets (3) on the back of the lamp. 4. Firmly grasp the center socket on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (2) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the CHMSL bulb (2) with the socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the CHMSL into the opening in the rear cab roof header panel. 7. Install and tighten the two screws (passenger side first) that secure the CHMSL to the header panel. Tighten the screws to 2 N.m (20 in. lbs.). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Page 8702 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Clearance Lamp > Clearance Lamp Bulb > Component Information > Service and Repair Clearance Lamp Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cab clearance lamp (1) from the roof panel. 3. Pull the base of the bulb (3) straight out of the socket (2). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Reinstall the cab clearance lamp (1) onto the roof panel. 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Cornering Lamp: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 8711 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams Lamp - Glove Box Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 8716 Glove Box Lamp: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window (3) in the instrument panel glove box opening (1) to access the bulb on the side of the glove box lamp and switch unit (2). 4. Pull the base of the bulb straight out of the bulb holder. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Reach through the window (3) in the instrument panel glove box opening (1) to align the base of the bulb with the bulb holder on the side of the glove box lamp and switch unit (2). 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Close the glove box door. 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information > Service and Repair > Page 8720 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Daytime Running Lamp: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 8725 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Page 8726 Daytime Running Lamp: Description and Operation Vehicles manufactured for sale in Canada illuminate the high beam filament of both headlamp bulbs at a reduced intensity when the engine is running, the parking brakes are released and the exterior lamps are turned off. The TIPM must be programmed with the appropriately for this feature to be enabled. Once enabled, anytime the TIPM receives electronic messages over the CAN data bus from the PCM indicating the engine is running and from the EMIC indicating the status of the headlamp switch exterior lighting input is Off, the TIPM See: Maintenance/Fuses and Circuit Breakers/Fuse/Locationsprovides a pulse width modulated voltage output to the proper headlamp bulb filaments through the right and left high beam feed circuits to produce illumination at a reduced intensity. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Technical Service Bulletins > Page 8727 Daytime Running Lamp: Testing and Inspection Daytime Running Lamps NOTE: Before performing the following tests, determine whether the headlamp low and high beams operate. If the headlamp low and high beams are also inoperative, diagnose and repair that problem before attempting to repair the Daytime Running Lamps. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Center Bezel Lamp Dome Lamp Bulb: Service and Repair Center Bezel Lamp WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel lamp unit (4) from the instrument panel center support structure. 3. Depress the latch tab (2) and slide the hood (1) off of the end of the lamp housing. 4. Pull the base of the bulb (3) straight out of the bulb holder within the lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. an incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the center bezel lamp bulb (3) with the bulb holder within the lamp housing (4). 2. Push the bulb straight into the bulb holder until the base is firmly seated. 3. Slide the hood (1) over the end of the lamp housing until the latch tab (2) snaps into place. 4. Reinstall the lamp unit into the instrument panel center support structure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Center Bezel Lamp > Page 8733 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Center Bezel Lamp > Page 8734 Dome Lamp Bulb: Service and Repair Dome Lamp Single Lamp - Bulb NOTE: There are two types of single lamp dome lamps available in this model: one with a switch that is activated by depressing the lamp lens, and one without a switch. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the dome lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the dome lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the ends of the bulb (3) with the two bulb holders within the dome lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the housing. 4. Reconnect the battery negative cable. Dual Lamp - Bulb REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Center Bezel Lamp > Page 8735 1. Disconnect and isolate the battery negative cable. 2. Remove the dome lamp (2) from the headliner. 3. With the lamp lens (1) in the open position, carefully unsnap the bulb (3) from the two bulb holders within the dome lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. With the dome lamp lens (1) in the open position, align the ends of the bulb (3) with the two bulb holders within the dome lamp housing (2). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Reinstall the lamp into the headliner. 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro- Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Controller Area Network (CAN) data bus. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic message inputs or outputs used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair Fog/Driving Lamp Bulb: Service and Repair CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under and behind the front fascia to access the front fog lamp housing (1) on the back of the front bumper (4). 3. Disconnect the wire harness connector (3) from the fog lamp bulb (2). 4. Firmly grasp the bulb on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the bulb straight out from the keyed opening in the housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the fog lamp bulb (2) with the keyed opening on the back of the front fog lamp housing (1). 2. Insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. The bulb connector receptacle should be pointed straight downward. 4. Reconnect the wire harness connector (3) to the bulb. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Indicator > Component Information > Description and Operation Fog/Driving Lamp Indicator: Description and Operation A fog lamp indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with optional fog lamps, this indicator is electronically disabled. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The fog lamp indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Front Fog Light in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when the it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The fog lamp indicator is serviced as a unit with the instrument cluster. The fog lamp indicator gives an indication to the vehicle operator whenever the optional fog lamps are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The fog lamp indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the fog lamp indicator for the following reasons: - Fog Lamp-On Message - Each time the cluster receives a fog lamp-on message from the TIPM indicating the fog lamp circuit is energized, the fog lamp indicator will be illuminated. The indicator remains illuminated until the cluster receives a fog lamp-off message from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the fog lamp indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors a hard wired input from the headlamp switch to determine the selected fog lamp switch status. The instrument cluster then sends the proper fog lamp-on and lamp-off messages to the TIPM over the CAN data bus. The TIPM activates the fog lamp circuit then sends the proper fog lamp indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the fog lamp indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the fog lamp system, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the fog lamp indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging Hazard Warning Lamps: Technical Service Bulletins Lighting - Information On Exterior Lamp Lens Fogging NUMBER: 23-035-07 GROUP: Body DATE: August 08, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-041-06, DATED SEPTEMBER 27, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Exterior Lamp - Lens Fogging MODELS: 2006 - 2008 (CS) Pacifica 2006 - 2008 (DC/DM) Ram Truck - Cab & Chassis (3500/4500/5500) 2006 - 2008 (DR/DH/D1) Ram Truck - Pick-up (1500/2500/3500) 2006 - 2008 (HB/HG) Durango/Aspen 2007 - 2008 (JK) Wrangler 2006 (JR) Stratus/Sebring 2006 - 2007 (JR27) Sebring Convertible 2007 - 2008 (JS) Sebring/Avenger 2008 (JS27) Sebring Convertible 2007 - 2008 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2008 (KK) Liberty/Cherokee 2006 - 2008 (LX/LE) 300/Magnum/Charger 2007 - 2008 (MK49) Compass 2007 - 2008 (MK74) Patriot 2006 - 2008 (ND) Dakota 2007 - 2008 (PM) Caliber 2006 - 2008 (PT) PT Cruiser 2006 - 2007 (RS/RG) Town & Country/Caravan/Voyager 2008 (RT) Town & Country/Caravan/Voyager 2006-2008 (WK/WH) Grand Cherokee 2006 - 2008 (XK/XH) Commander DISCUSSION: Some customers may report that on occasion, vehicle exterior lamp assemblies are fogged with a light layer of condensation on the inside of the lenses. This may be reported after the lamps have been turned on and brought up to operating temperature, turned off, and then rapidly cooled by cold water (such as rain, or the water from a car wash). Lens fogging can also occur under certain atmospheric conditions after a vehicle has been parked outside overnight (i.e., a warm humid day followed by clear cool night). This will usually clear as atmospheric conditions change to allow the condensation to change back into a vapor. Turning the lamps on will usually accelerate this process. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Technical Service Bulletins > Lighting - Information On Exterior Lamp Lens Fogging > Page 8750 A lamp that has large amounts of water droplets visible on most internal surfaces indicates a problem with the lamp sealing that has allowed water to enter the lamp. In this instance, the customer is likely to report that moisture in the lamp is always present and never disappears. A lamp that exhibits internal moisture permanently should be replaced. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Lamps: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8753 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8754 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8755 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8756 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8757 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8758 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8759 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8760 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8761 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8762 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8763 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8764 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8765 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8766 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8767 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8768 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8769 Hazard Warning Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8770 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8771 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8772 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Page 8773 Hazard Warning Lamps: Description and Operation The hazard warning system includes the EMIC, the TIPM and the multi-function switch on the steering column. The EMIC monitors a hard wired multiplex input from the multi-function switch to determine the status of the hazard warning switch, then sends the appropriate electronic hazard switch status messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps. The TIPM also sends the appropriate electronic messages back to the EMIC to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the EMIC electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Diagrams > Page 8774 Hazard Warning Lamps: Testing and Inspection Hazard Warning Lamps NOTE: Before performing the following tests, confirm whether the left and right turn signals operate satisfactorily. If the turn signals are inoperative or operate improperly, diagnose and repair that problem before attempting to repair the Hazard Warning Lamps. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair REMOVAL CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the headlamp bulb socket (2) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb unit straight out from the keyed opening in the housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the headlamp socket and bulb unit (2) with the keyed opening on the back of the front lamp unit housing (1). 2. Insert the socket and bulb into the housing until the socket is firmly seated. 3. Rotate the socket clockwise about 30 degrees to lock it into place. 4. Reinstall the front lamp unit onto the front fender. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8782 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8783 Switch - Headlamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8784 Headlamp Switch: Description and Operation The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three detent position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary "Push" function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. On models with optional fog lamps the rotary knob also has the text "PUSH" and an International Control and Display Symbol icon for Front Fog Light applied to it. The thumbwheel is also plastic and knurled. The cargo lamp push button is plastic with a smooth finish and the text "CARGO" applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if inoperative or damaged, it must be replaced. The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. - Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or deenergizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned On. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome defeat, dome on, parade/funeral mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and/or the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8785 The headlamp switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to and PWM processing of the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8786 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the cluster bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the wire harness connector from the back of the headlamp switch. Headlamp Part 1 Headlamp Part 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8787 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the inoperative headlamp switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 8788 Headlamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. INSTALLATION 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 N.m (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation Hi-Beam Indicator Lamp: Description and Operation A high beam indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The high beam indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for High Beam in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in blue through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. The high beam indicator gives an indication to the vehicle operator whenever the headlamp high beams are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hard wired multiplex input received by the cluster from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit. The high beam indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the high beam indicator for the following reasons: - High Beam Headlamps-On Input - Each time the cluster detects a high beam headlamps-on input from the headlamp beam select switch circuitry of the multi-function switch on the washer/beam select switch mux circuit, the headlamp high beams and the high beam indicator will be illuminated. The headlamp high beams and the high beam indicator remain illuminated until the cluster receives a high beam headlamps-off input from the multi-function switch, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the high beam indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster continually monitors the headlamp switch and the multi-function switch to determine the proper headlamp low beam and high beam control. The instrument cluster then sends the proper low beam and high beam lamp-on and lamp-off messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus and turns the high beam indicator on or off accordingly. For further diagnosis of the high beam indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the headlamps, or the headlamp switch and multi-function switch inputs to the instrument cluster that control the high beam indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8796 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams Switch - Horn Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 8800 Horn Switch: Description and Operation The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Diagrams > Page 8801 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair License Plate Bulb: Service and Repair NOTE: This procedure is for pick-up models only. On cab and chassis models the license plate lamp is integral to the left rear lamp unit. The park/ brake/turn signal bulb within the left rear lamp unit provides illumination for the license plate lamp function on all cab and chassis models. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Reach under the rear bumper near the center to access the back of either of the two license plate lamp housings (3). 3. Firmly grasp the socket (2) on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb (1) straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (1) with the license plate lamp socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the license plate lamp housing (3). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Bulb - Without Sunroof Map Light Bulb: Service and Repair Bulb - Without Sunroof NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small thin-bladed screwdriver, gently pry between each side of the lamp lens and the overhead console housing (1) to unsnap the pivot tabs (3) on the lens from the pivots in the lamp housing. 3. With the lens disengaged from both pivots, pull the front of the lens forward far enough to disengage the tab (2) on the rear edge of the lens from the slot in the rear of the overhead console lamp housing. 4. Remove the lens from the housing. 5. Carefully unsnap the bulb (2) from the two bulb holders (1) within the overhead console lamp housing. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Bulb - Without Sunroof > Page 8811 1. Align the ends of the bulb (2) with the two bulb holders (1) within the overhead console lamp housing. 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Position the lens tab (2) into the slot in the rear of the overhead console (1) lamp housing. 4. Align the pivot tabs (3) on each side of the lens with the pivots within the overhead console lamp housing. 5. Press firmly and evenly on the lens over both pivot locations until both pivot tabs snap back onto the pivots within the housing. 6. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair > Bulb - Without Sunroof > Page 8812 Map Light Bulb: Service and Repair Bulb - With Sunroof NOTE: On vehicles equipped with an optional overhead console the standard front dome lamp is replaced by two combination dome and reading lamps that are integral to the console housing. Each of these lamps is controlled by the door ajar switches on the courtesy lamp circuit, but also are independently controlled by a switch that is activated by depressing the lamp lens. The bulb types and service procedures are identical for both of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (3) from the headliner. 3. Firmly grasp the back of the reading lamp bulb socket (1) and unsnap it from the overhead console lamp housing. 4. Pull the socket and bulb (2) straight out from the keyed opening in the lamp housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the overhead console reading lamp bulb (2) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of lamp housing in the overhead console. 4. Insert the socket and bulb into the housing and press firmly on the back of the socket until it snaps into place and is firmly seated. 5. Reinstall the overhead console onto the headliner. 6. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Bulb - Front Side Marker Marker Lamp Bulb: Service and Repair Bulb - Front Side Marker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the front side marker bulb socket (5) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb with the front side marker bulb socket (5). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Bulb - Front Side Marker > Page 8818 Marker Lamp Bulb: Service and Repair Bulb - Rear Fender NOTE: These lamps are used on pick-up models with dual rear wheels. A lamp with an amber lens is located on the rear fender ahead of each rear wheel opening, and a lamp with a red lens is located on the rear fender behind each rear wheel opening. The bulb types and service procedures are identical for all four of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using hand pressure, press the rear edge of the rear fender marker lamp lens/housing (4) toward the front of the vehicle against the spring pressure of the retaining clip, then pull the rear edge of the lamp outward to disengage it from the mounting hole in the rear fender. 3. Pull the lamp out from the rear fender far enough to access the bulb socket (1) on the back of the lamp lens/housing. 4. Firmly grasp the bulb socket on the back of the lamp lens/housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber O-ring seal (2) is properly installed and in good condition around the base of the bulb socket. 4. Align the socket and bulb with the keyed opening on the back of the rear fender marker lamp lens/housing (4). 5. Insert the socket and bulb into the housing until the socket is firmly seated. 6. Rotate the socket clockwise about 30 degrees to lock it into place. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Bulb - Front Side Marker > Page 8819 7. Engage the front edge of the marker lamp into the front edge of the mounting hole in the rear fender. 8. Using hand pressure, press the rear edge of the marker lamp lens/housing toward the front of the vehicle against the spring pressure of the retaining clip, then push the rear edge of the lamp into the rear of the mounting hole in the rear fender. 9. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Bulb - Front Side Marker > Page 8820 Marker Lamp Bulb: Service and Repair Bulb - Tailgate NOTE: This lamp is used on pick-up models with dual rear wheels. A lamp with a red lens and containing three bulbs is located on the outside of the tailgate below the tailgate latch release handle. The bulb types and service procedures are identical for all three of these bulbs. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the two screws that secure the outboard ends of the tailgate marker lamp lens/housing (1) to the outer tailgate panel. 3. Pull the marker lamp out from the tailgate far enough to access the sockets (2) on the back of the lamp housing. 4. Firmly grasp the marker lamp socket on the back of the lamp housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb (3) straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (3) with the socket (2). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the tailgate marker lamp lens/housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Position the marker lamp to the outer tailgate panel. 7. Install and tighten the two screws that secure the marker lamp lens/housing to the tailgate panel. Tighten the screws to 1 N.m (11 in. lbs.). 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 8825 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (3) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 8829 3. Align the socket and bulb (3) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 8834 Horn Relay: Description and Operation Dodge Ram Trucks from 2006 to 2009, do not use a horn relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Parking Lamp Relay: Locations Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 8838 Parking Lamp Relay: Description and Operation Dodge Ram Trucks, 2006-2009 all, do not use a parking lamp relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8842 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8848 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8849 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8850 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8851 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8852 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8853 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8854 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8855 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8856 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8857 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8858 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8859 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8860 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8861 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8862 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8863 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8864 Backup Lamp Switch: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8865 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8866 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8867 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8868 Switch - Backup Lamp (M/T 5.7L HD/Diesel M/T) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 8869 Backup Lamp Switch: Description and Operation Vehicles equipped with a manual transmission have a normally open, spring-loaded plunger type backup lamp switch (2). Vehicles with an optional electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the automatic transmission. The backup lamp switch is located in a threaded hole on the side of the manual transmission housing. The switch has a threaded body and a hex formation near the plunger end of the switch. An integral connector receptacle at the end of the switch opposite the plunger connects the switch to the vehicle electrical system through a take out and connector of the engine wire harness. When installed, only the switch connector and the hex formation are visible on the outside of the transmission housing. The backup lamp switch cannot be adjusted or repaired and, if inoperative or damaged, the entire switch unit must be replaced. The backup lamp switch controls the flow of battery voltage to the backup lamp bulbs through an output on the backup lamp feed circuit. The switch plunger is mechanically actuated by the gearshift mechanism within the transmission, which will depress the switch plunger and close the switch contacts whenever the reverse gear has been selected. The switch receives battery voltage through a fuse in the Totally Integrated Power Module (TIPM) on a fused ignition switch output (run) circuit whenever the ignition switch is in the On position. The backup lamp switch and circuits can be tested using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 8870 Backup Lamp Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Raise and support the vehicle. 3. Locate and disconnect the engine wire harness connector for the backup lamp switch. 4. Check for continuity between the two terminal pins in the backup lamp switch connector receptacle. a. With the gear selector lever in the Reverse position, there should be continuity. b. With the gear selector lever in any position other than Reverse, there should be no continuity. 5. If the switch fails either of these two continuity tests, replace the inoperative backup lamp switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8874 Switch - Stop Lamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8875 Brake Light Switch: Description and Operation The brake lamp switch (2) is a three circuit, springloaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, inoperative, or removed from its mounting position for any reason, it must be replaced with a new unit. The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned On and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch is diagnosed using conventional diagnostic tools and methods. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8876 Brake Light Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Disconnect and isolate the battery negative cable. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the inoperative brake lamp switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8877 Brake Light Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the brake lamp switch (2) near the support bracket on the lower steering column (1). 3. Disconnect the wire harness connector (3) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket. 5. Pull the switch straight back from the keyed hole to remove it from the bracket. 6. Discard the removed brake lamp switch. INSTALLATION 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket on the lower steering column (1). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (2) is firmly Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8878 seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Do not release or pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (4) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (3) to the brake lamp switch. 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8882 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8883 Switch - Multifuction Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8884 Combination Switch: Description and Operation The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (On and Off) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, low speed or high speed; and, an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is inoperative, or if the switch is damaged, the entire switch must be replaced as a unit. The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system Off. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned off, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected low or high beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the right turn signal circuitry, and, downward to activate the left turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8885 the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. When a turn signal is activated, the multifunction switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the washer mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the Off position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or deenergizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8886 Combination Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi- Function Switch Tests table. 4. If the switch fails any of the tests, replace the inoperative multi-function switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8887 Combination Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8888 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. INSTALLATION 1. Slide the multi-function switch (1) into the multifunction switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 8889 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation Door Switch: Description and Operation This vehicle has up to four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if inoperative or damaged, the door latch unit must be replaced. The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The door ajar switches are hard wired in series between a body ground and the Electro- Mechanical Instrument Cluster (EMIC). The EMIC reads the hard wired door ajar switch inputs through internal pull-ups, then uses these inputs to control many electronic functions and features of the vehicle. The EMIC also sends the proper switch status messages to other electronic modules over the Controller Area Network (CAN) data bus. The door ajar switches can be diagnosed and tested using conventional diagnostic tools and methods. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the CAN data bus, or the electronic message inputs or outputs used to convey door ajar switch status to other modules in the vehicle. The most reliable, efficient, and accurate means to diagnose the EMIC, the CAN data bus, and both the hard wired and electronic message inputs and outputs affected by the door ajar switch inputs requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the glove box door. 3. Reach through the window in the instrument panel (2) glove box opening behind the switch to access and depress the retaining latch on either side of the glove box lamp and switch unit (3). 4. While holding the retaining latch depressed, push the glove box lamp and switch unit out through the mounting hole in the face of the instrument panel. 5. Disconnect the wire harness connector (1) from the glove box lamp and switch. 6. Remove the lamp and switch unit from the instrument panel. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair > Page 8896 1. Position the glove box lamp and switch unit (3) to the instrument panel (2) glove box opening. 2. Reconnect the wire harness connector (1) to the lamp and switch unit. 3. Feed the wire harness back through the switch mounting hole. 4. Align the lamp and switch unit with the mounting hole in the instrument panel. 5. Using hand pressure, push the lamp and switch unit firmly and evenly into the mounting hole until it is fully seated. 6. Close the glove box door. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Left Side Of Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8900 Left Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8901 Switch - Headlamp Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8902 Headlamp Switch: Description and Operation The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Two different switches are used. The standard switch features a three detent position rotary knob (4) for exterior lighting control, a thumbwheel (2) for panel lamps dimming and interior lighting control, and a momentary push button (3) for cargo lamp control. An optional switch has a momentary "Push" function added to the rotary knob for front fog lamp control. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. On models with optional fog lamps the rotary knob also has the text "PUSH" and an International Control and Display Symbol icon for Front Fog Light applied to it. The thumbwheel is also plastic and knurled. The cargo lamp push button is plastic with a smooth finish and the text "CARGO" applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if inoperative or damaged, it must be replaced. The headlamp switch uses two resistor multiplexed outputs and one conventional output to control the many functions and features it provides. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions, and on a cargo lamp return circuit to control the cargo lamps. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Cargo Lamps Control - The cargo lamp push button on the headlamp switch is depressed to activate or deactivate the cargo lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate cargo lighting control outputs through its internal cargo lamp driver circuit. - Front Fog Lamps Control - For vehicles so equipped, the rotary knob on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM responds by energizing or deenergizing the front fog lamps and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the park lamp and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The TIPM also remembers which headlamp beams were last selected with the multi-function switch, and energizes those beams by default the next time the headlamps are turned On. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome defeat, dome on, parade/funeral mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and/or the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8903 The headlamp switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to and PWM processing of the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8904 Headlamp Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the cluster bezel and the headlamp switch from the instrument panel as a unit. 2. Disconnect the wire harness connector from the back of the headlamp switch. Headlamp Part 1 Headlamp Part 2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8905 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the inoperative headlamp switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 8906 Headlamp Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel (1) from the instrument panel. 3. Disconnect the wire harness connector (3) from the back of the headlamp switch (4). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (2) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. INSTALLATION 1. Position the headlamp switch (4) to the back of the cluster bezel (1). 2. Install and tighten the three screws (2) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 N.m (20 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector (3) to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams Switch - Horn Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 8910 Horn Switch: Description and Operation The horn switch is serviced as a unit with the driver airbag trim cover. The horn switch can not be serviced separately. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 8911 Horn Switch: Testing and Inspection The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a scan tool and the proper Diagnostic Procedures information. WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Bulb - Pick-Up Tail Light Bulb: Service and Repair Bulb - Pick-Up NOTE: The rear lamp unit contains three bulbs: park/turn signal, park/brake/side marker, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. 3. Remove the four screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp unit. 5. Pull the base of the backup (1), park/brake/side marker (2) or park/turn signal (3) lamp bulb straight out of the appropriate socket in the socket plate (5). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the backup (1), park/brake/side marker (2) or park/turn signal (3) lamp bulb with the appropriate socket in the socket plate (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Bulb - Pick-Up > Page 8917 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber sealing washer (4) is properly installed and in good condition around the base of each bulb on the socket plate. 4. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 5. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 6. Install and tighten the four screws (3) that secure the socket plate to the housing. Tighten the screws to 1 N.m (12 in. lbs.). 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Bulb - Pick-Up > Page 8918 Tail Light Bulb: Service and Repair Bulb - Cab and Chassis NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn signal/brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the backup lamp bulb (4), or the park/turn signal/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 N.m (20 in. lbs.). 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions Trailer Lamps: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8923 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8924 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8925 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8926 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8927 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8928 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8929 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8930 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8931 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8932 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8933 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8934 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8935 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8936 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8937 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8938 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8939 Trailer Lamps: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8940 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8941 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8942 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Diagram Information and Instructions > Page 8943 Trailer Lamps: Connector Views Wiring-Trailer Tow (Box Off) - 1 Way Wiring Trailer Tow 4 - Way Wiring-Trailer Tow 7 - Way Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring Trailer Lamps: Description and Operation Trailer Tow Wiring In addition to the trailer tow wiring provisions, the TIPM in all vehicles includes trailer tow battery, park lamp, and both right and left stop/turn feed output provisions. When the TIPM receives the appropriate inputs for normal park, turn signal, hazard warning or brake lamp operation, it responds by providing battery voltage through the appropriate trailer tow wiring feed circuits to synchronize the illumination and flash rate of the trailer park, brake and turn signal lamps with those of the tow vehicle. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Description and Operation > Trailer Tow Wiring > Page 8946 Trailer Lamps: Description and Operation Wiring-Trailer Tow The rear body wire harness on the rear frame (1) of all vehicles is equipped with a take out with a standard, light-duty 4-pin trailer tow connector (2) that is secured to the top of the trailer hitch platform (4) behind the rear bumper. Vehicles equipped with an optional factory-installed trailer towing package have a second take out with a connector (3) that plugs into a receptacle in the back of a heavy duty, sealed, 7-pin trailer tow connector that is located near the center of the rear bumper. Vehicles equipped with the trailer tow package also include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (1) that are stored in the glove box (2) when the vehicle is shipped from the factory. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The standard 4-pin trailer tow connector contains the following vehicle circuits: park/tail lamps, left stop/turn lamp, right stop/turn lamp, and ground. The optional trailer towing package 7-way connector contains the same circuits as the 4-pin connector plus the following additional circuits: backup lamp, trailer battery and electric brake. If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. Refer to the appropriate wiring information. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the truck battery while the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the vehicle glove box for type, location, and ampere rating of the fuse or circuit breaker. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Dodge Ram Trucks, 2006-2009 all,Trailer Tow lamp relay is not serviceable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 8950 Trailer Lighting Relay: Diagrams Dodge Ram Trucks, 2006-2009 all, do not use a trailer tow relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Left Steering Column Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8955 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8956 Switch - Multifuction Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8957 Combination Switch: Description and Operation The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (On and Off) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp high or low beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. - Washer Control - The multi-function switch control knob provides a momentary position for washer system operation. - Wiper Control - The multi-function switch control knob provides two continuous wipe switch positions, low speed or high speed; and, an intermittent wipe mode with five delay interval positions. The multi-function switch cannot be adjusted or repaired. If any function of the switch is inoperative, or if the switch is damaged, the entire switch must be replaced as a unit. The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the ElectroMechanical Instrument Cluster (EMIC) (also sometimes referred to as the Cab Control Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system Off. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The TIPM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned off, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the TIPM over the CAN data bus. The TIPM energizes or de-energizes the selected low or high beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the right turn signal circuitry, and, downward to activate the left turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that provides turn signals only until the control stalk is released. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8958 the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the left turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral Off position. When a turn signal is activated, the multifunction switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM energizes and flashes or de-energizes the selected left or right turn signal circuits. - Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the washer mode. The washer pump will continue to operate in the washer mode until the control knob is released. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic washer switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or de-energizing the washer pump in the washer mode. - Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous wiper detents, to one of five intermittent wiper detents, or to the Off position to select the wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic wiper switch status messages to the TIPM over the CAN data bus. The TIPM responds by energizing or deenergizing the wiper motor. The TIPM is programmed to operate the wiper motor at the selected low or high continuous wipe speed, and to provide the selected electronically controlled speed-sensitive intermittent wipe or wipe-after-wash mode features. The multi-function switch can be diagnosed using conventional diagnostic tools and methods. However, proper testing of the multiplexed inputs to the EMIC requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8959 Combination Switch: Testing and Inspection WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. 1. Remove the multi-function switch from the switch mounting housing on the steering column. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi- Function Switch Tests table. 4. If the switch fails any of the tests, replace the inoperative multi-function switch as required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8960 Combination Switch: Service and Repair WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver airbag from the steering wheel. 3. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 4. Remove the steering wheel from the steering column. 5. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 6. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 7. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 8. Remove the upper shroud from the lower shroud and the steering column. 9. Remove the one center screw that secures the lower shroud to the steering column (4). 10. Remove the lower shroud from the steering column. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8961 11. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 12. Remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 13. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. INSTALLATION 1. Slide the multi-function switch (1) into the multifunction switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 N.m (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch housing. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 8962 2 N.m (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 N.m (20 in. lbs.). 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 N.m (20 in. lbs.). NOTE: When reinstalling the steering wheel, be certain to index the yellow rubber booted engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 10. Reinstall the steering wheel onto the steering column. 11. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 12. Reinstall the driver airbag onto the steering wheel. 13. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation Turn Signal Cancel Cam: Description and Operation The turn signal cancel cam (3) is concealed within the steering column. The turn signal cancel cam consists of two lobes on a molded plastic ring that is snapped into the lower hub of the clockspring rotor. The clockspring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring (2) is secured to the multi-function switch mounting housing on the steering column and remains stationary. The rotor of the clockspring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If inoperative or damaged, the entire clockspring unit must be replaced. When the multi-function switch control stalk is moved to a latched turn signal position, a turn signal cancel actuator is extended from the inside surface of the switch housing toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the two cam lobes will contact the actuator, automatically cancelling the turn signal event and releasing the latched multi-function switch control stalk to the neutral position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Description and Operation Turn Signal Flasher: Description and Operation Dodge Ram Trucks, 2004-2009 All, do not use a turn signal flasher relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster, the left indicator to the left of the tachometer and the right indicator to the right of the speedometer. Each turn signal indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for "Turn Warning" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these icons from being clearly visible when they are not illuminated. A green Light Emitting Diode (LED) behind each cutout in the opaque layer of the overlay causes the icon to appear in green through the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. The turn signal indicators give an indication to the vehicle operator that the turn signal (left or right indicator flashing) or hazard warning (both left and right indicators flashing) have been selected and are operating. These indicators are controlled by transistors on the instrument cluster electronic circuit board based upon cluster programming, a hard wired multiplex input received by the cluster from the turn signal and hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, and electronic messages received from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. Each turn signal indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will allow this indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, each LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the turn signal indicators for the following reasons: - Turn Signal-On Input - Each time the cluster detects a turn signal-on input from the turn signal switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic turn signal switch status messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output and the flash rate for either the right or left turn signal lamps. The TIPM also sends the appropriate electronic messages back to the cluster to control the illumination and flash rate of the right or left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the cluster electronic circuit board that emulates the sound emitted by a conventional turn signal flasher. The turn signals and the turn signal indicators continue to flash on and off until the cluster receives a turn signal-off input from the multi-function switch, or until the ignition switch is turned to the Off position, whichever occurs first. Hazard Warning-On Input - Each time the cluster detects a hazard warning-on input from the hazard warning switch circuitry of the multi-function switch on the turn/hazard switch mux circuit, it sends the appropriate electronic hazard switch status messages to the TIPM over the CAN data bus. The TIPM responds to these messages by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps. The TIPM also sends the appropriate electronic messages back to the cluster to control the illumination and flash rate of the right and left turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the cluster electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The turn signals and the turn signal indicators continue to flash on and off until the cluster receives a hazard warning-off input from the multi-function switch. - Lamp Out Mode - After the instrument cluster sends an electronic turn signal on message to the TIPM over the CAN data bus, if the TIPM detects an inoperative turn signal lamp or circuit, it increases the flash rate for the remaining operative turn signals and sends an electronic message back to the instrument cluster. The cluster then increases the flash rate of the turn signal indicator(s) and the clicking rate of the electromechanical relay to provide an indication of the problem to the vehicle operator. - Actuator Test - Each time the cluster is put through the actuator test, the turn signal indicators will be turned on, then off again during the bulb check portion of the test to confirm the functionality of each LED and the cluster control circuitry. The instrument cluster continually monitors the multi-function switch and electronic messages from the TIPM to determine the proper turn signal and hazard warning system control. For further diagnosis of the turn signal indicators or the instrument cluster circuitry that controls the indicators, refer to testing. For proper diagnosis of the turn signal and hazard warning system, the multi-function switch, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the turn signal indicators, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Bulb - Park/Turn Signal Turn Signal Bulb: Service and Repair Bulb - Park/Turn Signal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front lamp unit (1) from the front fender. 3. Firmly grasp the park/turn signal bulb socket (3) on the back of the front lamp unit housing and rotate it counterclockwise about 30 degrees to unlock it. 4. Pull the socket and bulb straight out from the keyed opening in the housing. 5. Pull the base of the bulb (2) straight out of the socket (1). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the bulb (2) with the park/turn signal bulb socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Bulb - Park/Turn Signal > Page 8977 3. Align the socket and bulb (3) with the keyed opening on the back of the front lamp unit housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reinstall the front lamp unit onto the front fender. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Bulb - Park/Turn Signal > Page 8978 Turn Signal Bulb: Service and Repair Bulb - Pick-Up NOTE: The rear lamp unit contains three bulbs: park/turn signal, park/brake/side marker, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear lamp unit (1) from the end of the quarter panel. 3. Remove the four screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp unit. 5. Pull the base of the backup (1), park/brake/side marker (2) or park/turn signal (3) lamp bulb straight out of the appropriate socket in the socket plate (5). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the backup (1), park/brake/side marker (2) or park/turn signal (3) lamp bulb with the appropriate socket in the socket plate (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Bulb - Park/Turn Signal > Page 8979 2. Push the bulb straight into the socket until the base is firmly seated. 3. Be certain that a rubber sealing washer (4) is properly installed and in good condition around the base of each bulb on the socket plate. 4. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 5. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 6. Install and tighten the four screws (3) that secure the socket plate to the housing. Tighten the screws to 1 N.m (12 in. lbs.). 7. Reinstall the rear lamp unit onto the end of the quarter panel. 8. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Bulb - Park/Turn Signal > Page 8980 Turn Signal Bulb: Service and Repair Bulb - Cab and Chassis NOTE: The rear lamp unit contains two bulbs: the park/turn signal/brake/license plate, and the backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the four screws (1) that secure the lens (2) to the rear lamp unit housing (5). 3. Push the backup lamp bulb (4), or the park/turn signal/brake/license plate bulb (7) slightly into its socket (3) or (6), then rotate the bulb counterclockwise about 30 degrees to unlock it. 4. Pull the base of the bulb straight out of the socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Align the base of the backup lamp bulb (4), or the park/turn signal/brake/license plate lamp bulb (7) with its socket (3) or (6). 2. Push the bulb straight into the socket until the base is firmly seated, then rotate the bulb clockwise about 30 degrees to lock it into place. 3. Position the lens (2) to the rear lamp unit housing (5). 4. Install and tighten the four screws (1) that secure the lens to the housing. Tighten the screws to 2 N.m (20 in. lbs.). 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair Underhood Light Bulb: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat bladed tool in the access slot between the underhood lamp housing (1) and the lamp lens (2). 3. Gently pry the lens until it unsnaps from the lamp housing. 4. Depress the bulb holder (2) inward far enough to disengage the terminals (3) of the bulb (1) and remove the bulb from the lamp housing (4). INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. 1. Engage one of the terminals (3) of the bulb (1) over the bulb holder closest to the connector receptacle on the underhood lamp housing (4). 2. Depress the other bulb holder (2) inward far enough to engage the remaining bulb terminal. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Light Bulb > Component Information > Service and Repair > Page 8985 3. Position the lens (2) over the lamp housing and use hand pressure to press the lens firmly and evenly onto the housing until it snaps into place. 4. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams Vanity Lamp: Diagrams Lamp-Vanity - Left (Light Package) Lamp-Vanity - Right (Light Package) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 8989 Vanity Lamp: Service and Repair NOTE: Vehicles equipped with optional vanity lamps have a mirror with a single lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for each of these lamps. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Insert a small flat-bladed screwdriver on either side near the top or the bottom between the vanity lamp lens (2) and the lamp housing of the sun visor (1). 3. Carefully pry the lens outward until it unsnaps from the lamp housing. 4. Using small needle-nose pliers, carefully grasp the bulb (2) and pull the base out of the lamp socket. INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 8990 1. Using small needle-nose pliers, carefully grasp the vanity lamp bulb (2) and align the base of the bulb with the socket in the lamp housing of the sun visor (1). 2. Push the bulb straight into the socket until the base is fully seated. 3. Insert one tab on the top or the bottom of the lens (2) into the appropriate slot at the top or bottom of the lamp housing. 4. Flex the lens far enough to engage the loose tab into its slot in the lamp housing. 5. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 8996 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams Switch - Power Sliding Backlite (Quad Cab/Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Diagrams > Page 9000 Heated Glass Element Switch: Description and Operation The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to On position a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes as long as the ignition switch is the Run position. After the initial time interval has expired, if the rear window defogger switch is turned on again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than Run, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 9005 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 9010 Heated Glass Element Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Rear Defogger Relay: Locations Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 9014 Rear Defogger Relay: Description and Operation Dodge Ram Trucks 2006-2009, do not use a heated window relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams Switch - Power Sliding Backlite (Quad Cab/Except Base) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Diagrams > Page 9019 Heated Glass Element Switch: Description and Operation The switch for the rear window defogger (EBL) system (1) is integrated into the A/C-heater control (2), which is located in the center of the instrument panel. When the rear window defogger switch is pressed to On position a request signal is sent on the CAN-B Bus to the totally integrated power module (TIPM) to operate the EBL system. When the high side driver in the totally integrated power module (TIPM) is energized, current is directed to the rear defogger grid lines and to the heated side view mirrors. The grid lines heat the glass to help clear the surface of fog or frost. An amber indicator will illuminate when the rear window defogger switch is activated. When activated, the switch sends a request signal to the to the totally integrated power module (TIPM) to energize the internal EBL high side driver to provide battery current to the rear window defogger grid lines and to the heated side view mirrors. NOTE: The EBL system turns off automatically after 15 minutes of initial operation. Each following activation cycle of the EBL system will last 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes as long as the ignition switch is the Run position. After the initial time interval has expired, if the rear window defogger switch is turned on again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will automatically shut off if the ignition switch is turned to any position other than Run, or it can be turned off manually by pressing the rear window defogger switch a second time. The rear window defogger switch is diagnosed using a scan tool. The rear window defogger switch and the rear window defogger indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Power Window Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9023 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9024 Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9025 Right Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9026 Left Rear Door (Right Side Similar) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9027 Power Window Switch: Diagrams Switch-Power Window - Left Rear Switch-Power Window - Passenger Switch-Power Window - Right Rear Switch-Window/Door Lock - Driver C1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9028 Switch-Window/Door Lock - Driver C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9029 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LED's are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LED's are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch refer to testing for service procedures. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to Power Windows/Testing and Inspection. If not OK, replace the faulty switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 9030 Power Window Switch: Service and Repair FRONT PASSENGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel. 4. Remove the 2 mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Rotate the assembly and remove the 3 screws (1) that attach the motor to the regulator. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair > Page 9036 1. Install the power motor to the regulator with the 3 screws (1). 2. Connect the electrical connector to the power motor. 3. Install the 2 mounting bolts (1). 4. Install the rear cab back panel. 5. Install the rear seats. 6. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Power Window Switch: Locations Center Stack Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9040 Left And Center Instrument Panel Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9041 Left Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9042 Right Front Door Premium Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9043 Left Rear Door (Right Side Similar) Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9044 Power Window Switch: Diagrams Switch-Power Window - Left Rear Switch-Power Window - Passenger Switch-Power Window - Right Rear Switch-Window/Door Lock - Driver C1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9045 Switch-Window/Door Lock - Driver C2 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9046 Power Window Switch: Testing and Inspection The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LED's are inoperative in both the power window and lock switch units and the power windows are inoperative, refer to testing. If the power windows operate, but any or all of the LED's are inoperative, the power window and lock switch units with the inoperative LED(s) is faulty and must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse in the Totally Integrated Power Module (TIPM) and the circuit breaker located near the park brake pedal. If OK, go to Step 2. If not OK, replace the faulty fuse or circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the fuse in the Totally Integrated Power Module (TIPM). If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch unit from the door trim panel (passenger doors). The drivers door switch is included with the window/lock switch refer to testing for service procedures. Unplug the wire harness connector from the switch unit. Power Window Switch Continuity Chart 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Off, Up and Down switch positions. If OK, refer to Power Windows/Testing and Inspection. If not OK, replace the faulty switch. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 9047 Power Window Switch: Service and Repair FRONT PASSENGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Remove the switch from the trim panel bezel. INSTALLATION 1. Insert switch to trim panel bezel. 2. Install door trim panel. 3. Connect battery negative cable. REAR PASSENGER REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel. 3. Gently pry switch from door trim panel. INSTALLATION 1. Install switch to door trim panel 2. Install door trim panel. 3. Connect battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-011-07 > Mar > 07 > Body Power Back Window Glass Keeper Loose Back Window Glass: Customer Interest Body - Power Back Window Glass Keeper Loose NUMBER: 23-011-07 GROUP: Body DATE: March 30, 2007 SUBJECT: Power Backlite Sliding Window - Glass Keeper Loose OVERVIEW: This bulletin involves installing a replacement backlite glass keeper MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500/2500/3500) NOTE: This bulletin applies to vehicles equipped with a power slider rear backlite (sales code GFE). SYMPTOM/CONDITION: The customer may notice that the glass keeper on the rear backlite has separated from the glass. DIAGNOSIS: If the above condition is present perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Use care not to scratch or damage glass surface or blackout area beyond what is covered by the keeper foot print. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-011-07 > Mar > 07 > Body Power Back Window Glass Keeper Loose > Page 9057 1. On the backlite stationary glass locate where the keeper is positioned (Fig. 1). 2. Remove old, loose urethane from the area under the keeper foot print. Make sure the remaining urethane has been trimmed to a level, smooth surface. 3. With sand paper or emery cloth, scuff the remaining urethane surface where the keeper is located. 4. Clean area of keeper with water and dry surface. 5. Fully close the power sliding window. 6. On the stationary glass, dry fit the new keeper to its normal position. The keeper should be centered in the middle of the blackout area. 7. Make sure that there is a 1 mm gap (0.040 inch) between the edge of the sliding glass and the edge of the keeper base. Make sure the sliding glass has been fully closed prior to measuring the 1 mm gap. 8. With the keeper properly positioned on the stationary glass, draw an outline of the keeper base on the glass blackout area with a pencil. NOTE: The technician may want to mask off the immediate area around the keeper outline to aid in possible removal of excess urethane (squeeze-out) after the new keeper is installed. 9. Fully open the power sliding window. 10. Apply approximately 2.5 grams of urethane to the keeper. Make sure the amount of urethane that is applied to the keeper fills the keeper cavity. There should be sufficient urethane applied to cover at least 80% of the keeper foot print area. 11. Using the outline made earlier as a guide, apply the keeper to the stationary glass. 12. Fully seat the keeper to the stationary glass to ensure that the urethane covers at least 80% of the keeper foot print area. 13. Use a piece of tape to hold the keeper in place. Allow the urethane to harden. 14. Carefully remove the tape and clean any excess urethane from the stationary glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-011-07 > Mar > 07 > Body Power Back Window Glass Keeper Loose > Page 9058 15. Apply a temporary piece of tape to hold the keeper in place overnight. NOTE: Be careful not to disturb the keeper and hardening urethane when closing the power sliding window. 16. Remove the tape the following day. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-010-07 > Mar > 07 > Body Water Leak Onto Rear Floor Area Back Window Glass: Customer Interest Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > Customer Interest for Back Window Glass: > 23-010-07 > Mar > 07 > Body Water Leak Onto Rear Floor Area > Page 9063 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-011-07 > Mar > 07 > Body - Power Back Window Glass Keeper Loose Back Window Glass: All Technical Service Bulletins Body - Power Back Window Glass Keeper Loose NUMBER: 23-011-07 GROUP: Body DATE: March 30, 2007 SUBJECT: Power Backlite Sliding Window - Glass Keeper Loose OVERVIEW: This bulletin involves installing a replacement backlite glass keeper MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500/2500/3500) NOTE: This bulletin applies to vehicles equipped with a power slider rear backlite (sales code GFE). SYMPTOM/CONDITION: The customer may notice that the glass keeper on the rear backlite has separated from the glass. DIAGNOSIS: If the above condition is present perform the Repair Procedure PARTS REQUIRED: REPAIR PROCEDURE: NOTE: Use care not to scratch or damage glass surface or blackout area beyond what is covered by the keeper foot print. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-011-07 > Mar > 07 > Body - Power Back Window Glass Keeper Loose > Page 9069 1. On the backlite stationary glass locate where the keeper is positioned (Fig. 1). 2. Remove old, loose urethane from the area under the keeper foot print. Make sure the remaining urethane has been trimmed to a level, smooth surface. 3. With sand paper or emery cloth, scuff the remaining urethane surface where the keeper is located. 4. Clean area of keeper with water and dry surface. 5. Fully close the power sliding window. 6. On the stationary glass, dry fit the new keeper to its normal position. The keeper should be centered in the middle of the blackout area. 7. Make sure that there is a 1 mm gap (0.040 inch) between the edge of the sliding glass and the edge of the keeper base. Make sure the sliding glass has been fully closed prior to measuring the 1 mm gap. 8. With the keeper properly positioned on the stationary glass, draw an outline of the keeper base on the glass blackout area with a pencil. NOTE: The technician may want to mask off the immediate area around the keeper outline to aid in possible removal of excess urethane (squeeze-out) after the new keeper is installed. 9. Fully open the power sliding window. 10. Apply approximately 2.5 grams of urethane to the keeper. Make sure the amount of urethane that is applied to the keeper fills the keeper cavity. There should be sufficient urethane applied to cover at least 80% of the keeper foot print area. 11. Using the outline made earlier as a guide, apply the keeper to the stationary glass. 12. Fully seat the keeper to the stationary glass to ensure that the urethane covers at least 80% of the keeper foot print area. 13. Use a piece of tape to hold the keeper in place. Allow the urethane to harden. 14. Carefully remove the tape and clean any excess urethane from the stationary glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-011-07 > Mar > 07 > Body - Power Back Window Glass Keeper Loose > Page 9070 15. Apply a temporary piece of tape to hold the keeper in place overnight. NOTE: Be careful not to disturb the keeper and hardening urethane when closing the power sliding window. 16. Remove the tape the following day. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Back Window Glass: All Technical Service Bulletins Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Back Window Glass: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 9075 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite Back Window Glass: Service and Repair Backlite BACKLITE REMOVAL CAUTION: It is difficult to salvage the backlite during the removal operation. The backlite is part of the structural support for the roof. The urethane bonding used to secure the glass to the fence is difficult to cut or clean from any surface. Since the molding is set in urethane, it is unlikely it would be salvaged. Before removing the backlite, check the availability from the parts supplier. NOTE: The backlite is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the backlite. 1. Roll down door glass. 2. Remove headliner (9). 3. On standard cab models remove the upper b-pillar trim (5), Refer to Trim Panel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 9078 4. On quad cab models remove the upper c-pillar trim (5), Refer to Trim Panel. 5. Bend backlite retaining tab (2) inward against glass. 6. Disconnect the rear window defogger electrical connector (if equipped). 7. Using a suitable pneumatic knife from inside the vehicle, cut urethane holding backlite frame to opening fence. 8. Separate glass (1) from vehicle. INSTALLATION 1. Clean urethane adhesive from around backlite opening fence. 2. If necessary, apply black-out primer to outer edge of replacement backlite frame (1). 3. If black-out primer was pre-applied on backlite, clean bonding surface with Isopropyl alcohol and clean lint free cloth. Allow 3 minutes for drying time. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 9079 4. Apply black-out primer to backlite opening fence. 5. Apply a 13 mm (0.5 in.) bead of urethane (4) around the perimeter of the window frame bonding surface (1). 6. Set glass (1) on lower fence and move glass forward into opening. 7. Firmly push glass (1) against rear window glass opening fence. 8. Bend tabs around edges of backlite opening fence to retain glass. 9. Clean excess urethane from exterior with MOPAR(R), Super Clean or equivalent. 10. Allow urethane to cure at least 24 hours (full cure is 72 hours). 11. Water test to verify repair before returning vehicle to service. 12. Connect the rear window defogger electrical connector, if equipped. 13. On standard cab models, install the upper b-pillar trim (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 9080 14. On quad cab models, install the upper c-pillar trim (5). 15. Install the headliner (9). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Backlite > Page 9081 Back Window Glass: Service and Repair Backlite Vent Glass BACKLITE VENT GLASS REMOVAL 1. Slide the upper run channel (1) out of the window frame (2). 2. Slide the vent glass (3) upward to remove from the lower window frame (2). 3. Lower the glass (3) out of the upper window frame (2) and remove. INSTALLATION 1. Slide the vent glass (3) upper edge into window frame (2) and insert the lower edge into the lower molding. 2. Position the upper run channel (1) into the window frame (2) and slide it into place. 3. Verify vent glass (3) operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (4) and separate the belt molding (1) from the door (5) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (5) flange and seat fully. 2. Install the screw (4). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9087 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove the door glass. 2. Separate the front door glass run weatherstrip (2) out of the door frame (5) and remove through the window opening. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9088 NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the front door glass run weatherstrip (2) into the door (5) through the window opening. 2. Position the weatherstrip into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip between the corners and then down the sides firmly. 4. Install the door glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9089 Front Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT-ALL MODELS 1. Raise the window glass to the full up position and remove the window regulator. 2. Loosen the two bolts (2 and 3) that secure the front glass run channel (1) to the door (5). 3. Slide the front glass run channel upward and disengage it from the door. 4. Remove the front glass run channel from the door through the door panel opening (4). 5. If required, remove the weatherstrip from the front glass run channel. REAR-QUAD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the lower bolt (1) that secures the rear glass run channel (3) to the door. 3. Loosen the upper bolt (4) that secures the rear glass run channel to the door. 4. Slide the rear glass run channel upward and disengage the upper screw from the door. 5. Remove the rear glass run channel from the door through the door panel opening (2). 6. If required, remove the weatherstrip from the rear glass run channel. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9090 REAR-STANDARD CAB 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the rear glass run channel (2) to the door. 3. Remove the rear glass run channel from the door through the door panel opening (3). 4. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT-ALL MODELS 1. If removed, install the weatherstrip onto the front glass run channel (1). 2. Position the front glass run channel into the door (5) through the door panel opening (4). 3. Engage the two bolts (2 and 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR-QUAD CAB Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9091 1. If removed, install the weatherstrip onto the rear glass run channel (3). 2. Position the rear glass run channel into the door through the door panel opening (2). 3. Engage the upper bolt (4) that secures the rear glass run channel to the door. 4. Install the lower bolt (1) that secures the rear glass run channel to the door. Tighten both the upper and lower bolts to 10 N.m (89 in.lbs.). 5. Install the window regulator and verify correct window operation. REAR-STANDARD CAB 1. If removed, install the weatherstrip onto the rear glass run channel (2). 2. Position the rear glass run channel into the door through the door panel opening (3). 3. Install the two bolts (1) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9092 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (3). 2. Separate the belt molding (1) from the door (3) mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (1) and seat onto the door (3) mounting flange fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9093 2. Install the door trim panel (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel Rear Door Window Glass Weatherstrip: Service and Repair Glass Run Channel GLASS RUN CHANNEL REMOVAL FRONT 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. Mega Cab Models 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (1 & 3) that secure the front glass run channel (2) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the front glass run channel. REAR Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 9099 1. Raise the window glass to the full up position and remove the window regulator. 2. Remove the two bolts (2) that secure the rear glass run channel (1) to the door and remove the run channel through the door panel opening. 3. If required, remove the weatherstrip from the rear glass run channel. INSTALLATION FRONT 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Mega Cab Models Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 9100 1. If removed, install the weatherstrip onto the front glass run channel (2). 2. Position the front glass run channel into the door through the door panel opening. 3. Install the two bolts (1 & 3) that secure the front glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. REAR 1. If removed, install the weatherstrip onto the rear glass run channel (1). 2. Position the rear glass run channel into the door through the door panel opening. 3. Install the two bolts (2) that secure the rear glass run channel to the door. Tighten the bolts to 10 N.m (89 in.lbs.). 4. Install the window regulator and verify correct window operation. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 9101 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Outer Belt Molding REAR DOOR OUTER BELT MOLDING REMOVAL 1. Remove the screw (3) and separate the belt molding (1) from the door (2) flange from the back to the front. INSTALLATION 1. Position the belt molding (1) onto the door (2) flange and seat fully. 2. Install the screw (3). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 9102 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Glass Run Weatherstrip REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Lower the glass. 2. Separate the rear door glass run weatherstrip (5) out of the door frame (2) and remove through the window opening. INSTALLATION NOTE: A mixture of soap and water may be used to aid installation of the weatherstrip into the corners. 1. Position the rear door glass run weatherstrip (5) into the door (2) through the window opening. 2. Position the weatherstrip (5) into the upper corners and seat firmly. 3. From back to front, seat the weatherstrip (5) between the corners and then down the sides firmly. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 9103 Rear Door Window Glass Weatherstrip: Service and Repair Rear Door Inner Belt Molding REAR DOOR INNER BELT MOLDING REMOVAL 1. Remove the door trim panel (5). 2. Separate the belt molding (2) from the rear door mounting flange from the back to the front. INSTALLATION 1. Position the belt molding (2) and seat onto the rear door mounting flange fully. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Glass Run Channel > Page 9104 2. Install the door trim panel (5). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair Back Window Regulator: Service and Repair BACKLITE VENT GLASS-REGULATOR REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the rear seats. 3. Remove the rear cab back panel, Refer to Trim Panel. 4. Remove the two mounting bolts (1). 5. Disconnect the electrical connector to the power motor. 6. Separate the cable housings from the glass track (1). 7. Disconnect the cable ends from the vent glass (2). 8. Separate the support clips (5) and remove the regulator assembly (3). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Back Window Regulator > Component Information > Service and Repair > Page 9109 1. Connect the cable ends to the vent glass (2). 2. Install the cable housings into the glass tracks (1). 3. Fasten the support clips (5). 4. Install the 2 mounting bolts (1). 5. Install the rear cab back panel. 6. Install the rear seats. 7. Connect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures Front Door Window Regulator: Procedures Manual REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9114 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Power REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9115 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9116 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9117 Front Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9118 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9119 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Front Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Procedures > Page 9120 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures Rear Door Window Regulator: Procedures Manual REMOVAL 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 7. Remove the two bolts (5) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9125 1. Install the window regulator (4) through the opening in the door (2). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolt (5) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown and remove the manual window crank. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Install the waterdam. 9. Install the inner belt molding. Power REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9126 1. Remove the inner belt molding. 2. Remove the waterdam. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass to the window regulator (2) through the two sight windows (3 and 4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (4) and remove the two nuts (3) that secure the regulator stabilizer (1) to the door (2). 8. Remove the bolt (5) that secures the window regulator to the door and loosen the other two regulator bolts (7). 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (6). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9127 1. Connect the door wire harness (6) to the window regulator (4) and install the regulator through the opening in the door (2). 2. Engage the two regulator bolts (7) to the door. 3. Install the bolt (5) that secure the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in. lbs.). 4. Position the regulator stabilizer (1) into the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in. lbs.). 5. Raise the window regulator (2) to the position shown. 6. Support the window glass and remove the wooden wedge or equivalent. 7. Position the window glass to the window regulator and install the two nuts (1) thought the two sight windows (3 and 4). Tighten the nuts to 10 N.m (89 in. lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9128 Rear Door Window Regulator: Removal and Replacement Window Regulator-Power WINDOW REGULATOR-POWER REMOVAL 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Remove the electric window switch from the door trim panel and connect it to the door wire harness. 4. Raise the door glass to the position shown. 5. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 6. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 7. Lower the window regulator (2) and remove the two nuts that secure the regulator stabilizer to the door. 8. Remove the lower bolt (1) that secures the window regulator to the door and loosen the other two regulator bolts. 9. Slide the window regulator upward and disengage the two regulator bolts from the door. 10. Remove the window regulator through the opening in the door and disconnect the door wire harness (3). INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9129 1. Connect the door wire harness (3) to the window regulator (2) and install the regulator through the opening in the door. 2. Engage the two upper regulator bolts (1) to the door. 3. Install the lower regulator bolt that secures the window regulator to the door and tighten all three regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer into the door and install the two nuts. Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator (3) through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Disconnect the electric window switch from the door wire harness and reinstall the switch onto the door trim panel. 9. Install the waterdam. 10. Install the inner belt molding. Window Regulator-Manual WINDOW REGULATOR-MANUAL REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9130 1. Remove the inner belt molding, Refer to Weatherstrip. 2. Remove the waterdam, Refer to Rear Door Panel. 3. Reinstall the manual window crank and raise the door glass to the position shown. 4. Remove the two nuts (1) that secure the door glass (2) to the window regulator (3) through the speaker opening (5) and the sight window (4) and disengage the door glass from the regulator. 5. Position the door glass to the full up position and secure the glass using a wooden wedge or an equivalent. 6. Lower the window regulator (5) and remove the two nuts (3) that secure the regulator stabilizer (4) to the door (1). 7. Remove the two bolts (2) that secure the window regulator to the door and loosen the other two regulator bolts (6). 8. Slide the window regulator upward and disengage the two regulator bolts from the door. 9. Remove the window regulator through the opening in the door. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Procedures > Page 9131 1. Install the window regulator (5) through the opening in the door (1). 2. Engage the two regulator bolts (6) to the door. 3. Install the two bolts (2) that secure the window regulator to the door and tighten all four regulator bolts to 10 N.m (89 in.lbs.). 4. Position the regulator stabilizer (4) onto the door and install the two nuts (3). Tighten the nuts to 10 N.m (89 in.lbs.). 5. Raise the window regulator (3) to the position shown and remove the manual window crank. 6. Support the door glass (2) and remove the wooden wedge or equivalent. 7. Position the door glass to the window regulator and install the two nuts (1) that secure the door glass to the window regulator through the sight window (4) and the speaker opening (5). Tighten the nuts to 10 N.m (89 in.lbs.). 8. Install the waterdam. 9. Install the inner belt molding . Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: Customer Interest Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 9140 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area Window Seal: All Technical Service Bulletins Body - Water Leak Onto Rear Floor Area NUMBER: 23-010-07 GROUP: Body DATE: March 24, 2007 SUBJECT: Water Leak Due To Small Void In Backlite Sealer OVERVIEW: This bulletin involves inspection and correction of a backlite sealer void. MODELS: 2006 - 2007 (DR/DH/D1) Ram Truck (1500 / 2500 / 3500) 2006 - 2007 (ND) Dakota SYMPTOM/CONDITION: The customer may experience the presence of water on or under the rear area floor carpet. DIAGNOSIS: This condition may be due to water leaking past a small void in the adhesive used to retain the backlite glass to the body panel. The backlite glass is retained to the vehicle body by urethane adhesive. If the water leak is due to a small void in the backlite glass adhesive then perform the Repair Procedure. NOTE: DO NOT replace the backlite glass because of a small void in the backlite glass adhesive. Due to the possibility of backlite glass breakage during the backlite removal process, it is recommended that a flowable sealer be applied to seal a small void in the backlite adhesive. PARTS REQUIRED: REPAIR PROCEDURE: 1. Along the outside backlite-to-body panel urethane adhesive joint, dry off the affected area(s) with clean compressed air. 2. From outside the vehicle, apply Silicone Windshield and Glass Sealer to the affected area(s) in the backlite urethane adhesive joint. 3. Allow sufficient time to allow the newly applied sealer to dry. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-010-07 > Mar > 07 > Body - Water Leak Onto Rear Floor Area > Page 9146 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass Windshield: Customer Interest Body - Circular/Ring Marks on Glass NUMBER: 23-035-05 GROUP: Body DATE: July 26, 2005 SUBJECT: Circular/Ring Marks On Glass MODELS DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as "rings" or "circles" that won't clean off with standard glass cleaners. To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami(R)) or a glass polish containing Cerium Oxide. CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax(R), Comet(R), Soft-Scrub(R), etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass > Page 9155 PARTS REQUIRED CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-047-06 > Oct > 06 > Body - Windshield Crack Diagnosis Windshield: All Technical Service Bulletins Body - Windshield Crack Diagnosis NUMBER: 23-047-06 GROUP: Body DATE: October 21, 2006 SUBJECT: Cracked Windshield MODELS: 2006 - 2007 (CS) Pacifica 2006 - 2007 (DC) Ram Cab & Chassis 2006 - 2007 (DR/DH/D1) Ram Truck 2006 - 2007 (HB) Durango 2007 (HG) Aspen 2006 (TJ) Wrangler/Wrangler Unlimited 2007 (JK) Wrangler/Wrangler Unlimited 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 2007 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2006 - 2007 (LE) 300C/300C Touring (International Market) 2006 - 2007 (LX) 300/Magnum/Charger 2007 (MK49) Compass 2006 - 2007 (ND) Dakota 2007 (PM) Caliber 2006 - 2007 (PT) Chrysler PT Cruiser 2006 - 2007 (RS) Town & Country/Caravan 2006 - 2007 (RG) Chrysler Voyager (International Market) 2006 - 2007 (WK) Grand Cherokee 2006 - 2007 (WH) Grand Cherokee (International Market) 2006 - 2007 (XK/XH) Commander 2006 (ZB) Viper 2006 - 2007 (ZH) Crossfire DISCUSSION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-047-06 > Oct > 06 > Body - Windshield Crack Diagnosis > Page 9161 Windshield cracks caused by an impact from a foreign object; (i.e. stone) are often difficult to identify. The following assessment should be used to verify the presence of an impact chip on the crack. If no obvious impact chip is present, run a ball point pen along the crack and feel for a slight drop or pit in the glass. If a slight drop or pit in the glass is present, this indicates a small impact caused the crack. If the molding contains a witness mark or dent from an impact, inspect under the molding for an impact chip in the same manner. POLICY: Cracks caused by an impact are not warrantable. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass Windshield: All Technical Service Bulletins Body - Circular/Ring Marks on Glass NUMBER: 23-035-05 GROUP: Body DATE: July 26, 2005 SUBJECT: Circular/Ring Marks On Glass MODELS DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as "rings" or "circles" that won't clean off with standard glass cleaners. To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami(R)) or a glass polish containing Cerium Oxide. CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax(R), Comet(R), Soft-Scrub(R), etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass > Page 9166 PARTS REQUIRED CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 23-047-06 > Oct > 06 > Body - Windshield Crack Diagnosis Windshield: All Technical Service Bulletins Body - Windshield Crack Diagnosis NUMBER: 23-047-06 GROUP: Body DATE: October 21, 2006 SUBJECT: Cracked Windshield MODELS: 2006 - 2007 (CS) Pacifica 2006 - 2007 (DC) Ram Cab & Chassis 2006 - 2007 (DR/DH/D1) Ram Truck 2006 - 2007 (HB) Durango 2007 (HG) Aspen 2006 (TJ) Wrangler/Wrangler Unlimited 2007 (JK) Wrangler/Wrangler Unlimited 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 2007 (KA) Nitro 2006 - 2007 (KJ) Liberty/Cherokee 2006 - 2007 (LE) 300C/300C Touring (International Market) 2006 - 2007 (LX) 300/Magnum/Charger 2007 (MK49) Compass 2006 - 2007 (ND) Dakota 2007 (PM) Caliber 2006 - 2007 (PT) Chrysler PT Cruiser 2006 - 2007 (RS) Town & Country/Caravan 2006 - 2007 (RG) Chrysler Voyager (International Market) 2006 - 2007 (WK) Grand Cherokee 2006 - 2007 (WH) Grand Cherokee (International Market) 2006 - 2007 (XK/XH) Commander 2006 (ZB) Viper 2006 - 2007 (ZH) Crossfire DISCUSSION: Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 23-047-06 > Oct > 06 > Body - Windshield Crack Diagnosis > Page 9172 Windshield cracks caused by an impact from a foreign object; (i.e. stone) are often difficult to identify. The following assessment should be used to verify the presence of an impact chip on the crack. If no obvious impact chip is present, run a ball point pen along the crack and feel for a slight drop or pit in the glass. If a slight drop or pit in the glass is present, this indicates a small impact caused the crack. If the molding contains a witness mark or dent from an impact, inspect under the molding for an impact chip in the same manner. POLICY: Cracks caused by an impact are not warrantable. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9173 Windshield: Service Precautions WARNING WINDSHIELD SAFETY PRECAUTIONS Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. - Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. - DaimlerChrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warranty and will restore a vehicle to the requirements of fmvss 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. - Be sure to refer to the urethane manufacturer's directions for curing time specifications and do not use adhesive after its expiration date. - Vapors that are emitted from the urethane adhesive or primer could cause personal injury or death. Use them in a well-ventilated area. - Skin contact with urethane adhesive should be avoided. Personal injury or death may result. - Always wear eye and hand protection when working with glass. Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield . Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9174 Windshield: Service and Repair REMOVAL 1. Remove inside rear view mirror (3). 2. Remove cowl grille (2). 3. Remove the a-pillar weatherstrip retainer (1), Refer to Weatherstrip. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9175 4. Remove the a-pillar trim panels (2), Refer to Trim Panel. 5. Remove the headliner (9) and from the inside of the vehicle, cut the upper urethane bonding from around windshield upper edge using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 6. From the outside of the vehicle, cut urethane bonding from the remaining sides of the windshield using a suitable sharp cold knife (C-4849). A pneumatic cutting device can be used but is not recommended. 7. Separate windshield from vehicle. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9176 WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield. This is to avoid pressurizing the passenger compartment if a door is slammed before the urethane is cured. The potential for water leaks can result. The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. 1. Place replacement windshield (1) into windshield opening and position glass in the center of the opening against the support spacers (3). Mark the outside surface of the glass at the support spacers (3) with a grease pencil or pieces of masking tape and ink pen to use as a reference (2) for installation. Remove replacement windshield from windshield opening. 2. Position the windshield (1) inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. By 4 in. By 20 in.) blocks (3), placed parallel 75 cm (2.5 ft.) apart. 3. Clean inside of windshield with MOPAR(R) Glass Cleaner and lint-free cloth. 4. Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint-free cloth. 5. Apply black-out primer onto the glass using the windshield molding as a guide. The primer should be 15 mm (5/8 in.) wide on the top and sides of the glass and 25 mm (1 in.) on the bottom of windshield. Allow at least three minutes drying time. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9177 6. Locate NEW support spacers (3) on support brackets and adjust to lowest height. 7. Position seven new foam spacers (4 and 3) on the inside surface of the windshield, flush with the lower and side edges. 8. Position three new foam spacers (1) on the inside surface of the windshield, at a minimum distance of 3 mm (0.12 in.) from the top edge of the windshield. 9. The urethane bead should be shaped in a triangular cross-section, this can be achieved by notching the tip of the applicator. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9178 10. Apply a 13 mm (1/2 in.) high and 10 mm (3/8 in.) wide bead of urethane around the perimeter of windshield (2). At the top, apply the bead 7 mm (1/4 in.) inboard from the glass edge. On the other three sides apply the bead 14 mm (0.55 in.) inboard from the glass edge. 11. Install the a-pillar trim (2). 12. With the aid of a helper, position the windshield (2) over the windshield opening. Align the reference marks at the bottom of the windshield to the support spacers (3). 13. Slowly lower windshield glass (2) to the fence opening guiding the lower corners into proper position. Beginning at the bottom and continuing to the top, push glass (2) onto fence along the A-Pillars. Push windshield (2) inward to the fence at the bottom corners. 14. Push windshield (2) upward, setting the windshield to roof gap to 1.5 mm (0.06 in.) to 3 mm (0.12 in.) and ratchet up the adjustable support Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 9179 brackets. 15. Using clean water, lightly mist the support spacers (3). 16. Clean excess urethane from exterior with MOPAR(R) Super Clean or equivalent. 17. Install cowl grille (2). 18. Install rear view mirror support bracket (4). 19. Install rear view mirror (3). 20. Install the a-pillar weatherstrip retainer (1). 21. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation Check Valve: Description and Operation A single washer system check valve is standard equipment on this model, and is installed in the washer system plumbing. The check valve is integral to the washer nozzle plumbing wye fitting (2) located in the cowl plenum area beneath the cowl plenum cover/grille panel near the base of the windshield. The check valve consists of a molded plastic body with a raised arrowhead (4) molded into its center section that indicates the direction of the flow through the valve, and three barbed hose nipples (1 and 3) formed in a wye configuration on the outside circumference of the center section of the valve body. The check valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The check valve provides more than one function in this application. It serves as a wye connector fitting between the engine compartment and washer nozzle sections of the washer supply hose. It prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a lengthy delay from when the washer switch is actuated until washer fluid was dispensed through the washer nozzles, because the washer pump would have to refill the washer plumbing from the reservoir to the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents washer fluid from siphoning through the washer nozzles after the washer system is turned Off. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure (5) unseats a diaphragm (3) from over a sump well within the valve by overriding the pressure applied to a piston (2) by a spring (1). With the diaphragm unseated, washer fluid is allowed to flow toward the two washer nozzles (4). When the washer pump stops operating, the spring pressure on the piston seats the diaphragm over the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. The check valve cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Description and Operation > Page 9184 Check Valve: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (5), disconnect the cowl plenum (4) and washer nozzle hoses (1 and 6) from the three barbed nipples of the check valve (2). 5. Remove the check valve from the underside of the cowl plenum cover/grille panel. INSTALLATION 1. Position the check valve (2) to the underside of the cowl plenum cover/grille panel (5). Be certain that the flow direction arrow molded into the check valve body is oriented towards the washer nozzles. 2. From the underside of the cowl plenum cover/grille panel, reconnect the cowl plenum (4) and washer nozzle hoses (1 and 6) to the three barbed nipples of the check valve. 3. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 4. Close and latch the hood. 5. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 9189 Wiper Relay: Description and Operation Dodge Ram 2006-2009, does not use a wiper relay. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9194 Switch - Washer Fluid Level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9195 Washer Fluid Level Switch: Description and Operation The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Controller Area Network (CAN) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT10 and diesel engines) or left (SRT10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch circuits may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the TIPM, the CAN data bus, or the electronic message inputs to or outputs from the instrument cluster and the TIPM that control the operation of the washer fluid visual and audible indications. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the TIPM, the CAN data bus or the electronic message inputs and outputs related to the washer fluid indicator requires the use of diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9196 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the right headlamp and dash wire harness 4. connector for the washer fluid level switch 3. from the switch connector receptacle. 4. Using a trim stick or another suitable wide flatbladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2) Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (3) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the right headlamp and dash wire harness 4. connector to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation Washer Fluid Level Indicator: Description and Operation A washer fluid indicator is standard equipment on all instrument clusters. This indicator is located in the lower portion of the tachometer dial face in the instrument cluster overlay. The washer fluid indicator consists of a stencil-like cutout of the International Control and Display Symbol Icon for "Windscreen Washer Fluid Level" in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the instrument cluster. The washer fluid indicator gives an indication to the vehicle operator that the fluid level in the washer reservoir is low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Totally Integrated Power Module (TIPM) over the Controller Area Network (CAN) data bus. The washer fluid indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic will only allow this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any position except On or Start. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the washer fluid indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the On position the washer fluid indicator is illuminated for about two seconds as a bulb test. - Washer Fluid Indicator Lamp-On Message - Each time the cluster receives a washer fluid indicator lamp-on message from the TIPM indicating that a low washer condition has been detected for sixty consecutive seconds, the washer fluid indicator is illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a washer fluid indicator lamp-off message for sixty consecutive seconds from the TIPM or until the ignition switch is turned to the Off position, whichever occurs first. The chime tone feature will only repeat during the same ignition cycle if the washer fluid indicator is cycled off and then on again by the appropriate washer fluid lamp messages from the TIPM. - Actuator Test - Each time the cluster is put through the actuator test, the washer fluid indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The TIPM continually monitors the washer fluid level switch in the washer reservoir to determine the level of the washer fluid. The TIPM then sends the proper washer fluid indicator lamp-on and lamp-off messages to the instrument cluster. For further diagnosis of the washer fluid indicator or the instrument cluster circuitry that controls the indicator, refer to testing. For proper diagnosis of the washer fluid level switch, the TIPM, the CAN data bus, or the electronic message inputs to the instrument cluster that control the washer fluid indicator, a diagnostic scan tool is required. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Right Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9203 Switch - Washer Fluid Level Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9204 Washer Fluid Level Switch: Description and Operation The washer fluid level switch (3) is a two-pin conductivity sensor with no moving parts mounted on the rearward facing side of the washer reservoir adjacent to the washer pump/motor unit in the engine compartment. Only the molded plastic switch mounting flange and the integral connector receptacle (4) are visible when the switch is installed in the reservoir. A short nipple formation (1) extends from the inner surface of the switch mounting flange, and a barb on the nipple is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. Two over-molded pins or electrodes (2) extend from the back of the nipple formation. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, the switch must be replaced. The washer fluid level switch uses fluid conductivity to monitor the level of the washer fluid in the washer reservoir. Electricity is conducted between the two switch pins or electrodes only when they are immersed in the washer fluid, which closes the switch circuit. When the fluid level in the washer reservoir falls below the pins, electrical current cannot be conducted and the switch becomes an open circuit, which signals a low fluid condition. In order to prevent an electrical charge from accumulating in the electrical leads of the switch, the switch receives current that is pulsed from the Totally Integrated Power Module (TIPM) located in the engine compartment near the battery. The TIPM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-on message to the instrument cluster over the Controller Area Network (CAN) data bus. The instrument cluster responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except SRT10 and diesel engines) or left (SRT10 and diesel engines only) headlamp and dash wire harness. The switch is connected in series between a sensor return circuit and the washer fluid switch sense input to the TIPM. The washer fluid level switch circuits may be diagnosed and tested using conventional diagnostic tools and procedures. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the TIPM, the CAN data bus, or the electronic message inputs to or outputs from the instrument cluster and the TIPM that control the operation of the washer fluid visual and audible indications. The most reliable, efficient, and accurate means to diagnose the washer fluid level indicator, the instrument cluster, the TIPM, the CAN data bus or the electronic message inputs and outputs related to the washer fluid indicator requires the use of diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 9205 Washer Fluid Level Switch: Service and Repair REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose (1) from the barbed outlet nipple of the washer pump/motor unit (5) and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the right headlamp and dash wire harness 4. connector for the washer fluid level switch 3. from the switch connector receptacle. 4. Using a trim stick or another suitable wide flatbladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the washer reservoir sump (2). Care must be taken not to damage the reservoir. 5. Remove the switch from the reservoir. 6. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (2) Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the switch (3) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be pointed upward. 4. Reconnect the right headlamp and dash wire harness 4. connector to the switch connector receptacle. 5. Reconnect the removed washer hose (1) to the barbed outlet nipple of the washer pump/motor unit (5). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation Windshield Washer Hose: Description and Operation The washer plumbing consists of a small diameter rubber reservoir washer hose that is routed from the barbed outlet nipple of the electric washer pump/motor unit on the washer reservoir through a trough molded into the back of the reservoir above the washer pump to the engine compartment washer hose to the right side of the engine cooling module. On SRT10 models or those equipped with an optional diesel engine, the reservoir washer hose is routed through routing clips on the top of the radiator fan shroud from the washer reservoir on the left side of the radiator to the engine compartment washer hose on the right side of the radiator. The engine compartment washer hose is contained within the right headlamp and dash wire harness (2), which is routed through the engine compartment along the top of the right front fender wheel house to the dash panel. This hose is connected to the washer reservoir washer hose at one end (5) and to the cowl plenum washer hose at the other end (3) with molded plastic in-line fittings that have a barbed nipple on each end. The cowl plenum washer hose (4) is routed from the engine compartment into the cowl plenum area through a trough formation located near the right end of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to the washer system check valve/wye fitting on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose and the two washer nozzle hoses are routed through integral routing clips on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to one nipple on the wye fitting and the two washer nozzle hoses are connected to the other two nipples. The washer nozzle hoses are then routed along the underside of the cowl plenum cover/grille panel to the two washer nozzles. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are faulty or damaged, they must be replaced. Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor through the washer system plumbing and fittings to the two washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Pump - Washer-Windshield Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 9212 Windshield Washer Pump: Description and Operation The washer pump/motor unit (1) is located on the rearward facing surface of the washer reservoir, in the right (except SRT10 and diesel) or left (SRT10 and diesel only) front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a barbed inlet nipple (6) on the pump housing passes through a rubber grommet seal installed in a dedicated mounting hole of the washer reservoir. A removable molded plastic filter screen (7) inserted into the inlet nipple prevents most debris from entering the pump housing. When the pump is installed in the reservoir a barbed outlet nipple (5) on the pump housing connects the unit to the washer system through a short washer reservoir hose. The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap post (2) on the motor housing and a snap post receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle (3) on the top of the motor housing connects the unit to the vehicle electrical system. The washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced. The washer pump/motor unit features a small Direct Current (DC) electric motor. The motor is connected to the vehicle electrical system through a single take out and two-cavity connector of the right (except SRT10 and diesel) or left (SRT10 and diesel only) headlamp and dash wire harness. The motor is grounded at all times through another take out of the right (except SRT10 and diesel) or left (SRT10 and diesel only) headlamp and dash wire harness. On models except SRT10 or diesel, a single eyelet terminal connector is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. On SRT10 or diesel models, an eyelet terminal connector is secured by a ground screw to the left front fender inner shield in the engine compartment. The motor receives battery current on a washer pump/motor control circuit. The washer pump/motor control circuit is energized through a high side driver within the Totally Integrated Power Module (TIPM) whenever the TIPM receives an electronic message requesting washer system operation from the ElectroMechanical Instrument Cluster (EMIC) over the Controller Area Network (CAN) data bus. The EMIC monitors a resistor multiplexed hard wired input from the momentary washer switch contacts within the multi-function switch on the steering column to determine when it should issue the electronic message requesting washer system operation. Washer fluid is gravity-fed from the washer reservoir to the inlet side of the washer pump. When the pump motor is energized, the motor spins the rotor within the washer pump. The spinning pump rotor pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass. The washer pump/motor unit and the hard wired motor control circuit from the TIPM may be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the EMIC, the TIPM, the CAN data bus or the electronic messages used to control the operation of the washer pump/motor unit. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit, the EMIC, the TIPM, the CAN data bus, and the electronic messages for washer pump/motor unit control requires the use of a diagnostic scan tool. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 9213 Windshield Washer Pump: Service and Repair REMOVAL NOTE: The washer pump/motor unit can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. 2. Disconnect the washer hose from the barbed outlet nipple (8) of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse. 3. Disconnect the right headlamp and dash wire harness connector from the washer pump/motor unit connector receptacle (1). 4. Firmly grasp the top of the washer pump/motor housing. 5. Pull lightly outward on the top of the washer pump/motor housing, away from the washer reservoir (6) far enough to disengage the snap post (2) on the top of the motor from the receptacle (3) in the reservoir. 6. Pull the washer pump/motor unit straight out from the washer reservoir far enough to disengage the barbed pump inlet nipple (7) from the rubber grommet seal (4) in the reservoir. 7. Remove the washer pump/motor unit from behind the washer reservoir. 8. Remove the rubber grommet seal from the washer pump mounting hole in the reservoir and discard. INSTALLATION 1. Install a new rubber grommet seal (4) into the washer pump mounting hole in the washer reservoir (6). Always use a new rubber grommet seal on the reservoir. 2. Position the barbed inlet nipple (7) of the washer pump to the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the washer pump/motor unit until the barbed inlet nipple is fully seated in the rubber grommet seal in the pump mounting hole of the reservoir. 4. Align the snap post (2) on the top of the pump motor housing with the snap post receptacle (3) in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the snap post snaps into the receptacle. 6. Reconnect the reservoir washer hose to the barbed pump outlet nipple (8). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 9214 7. Reconnect the right headlamp and dash wire harness connector to the washer pump/motor unit connector receptacle (1). 8. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 9. Reconnect the battery negative cable. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation Windshield Washer Reservoir: Description and Operation Except on SRT10 and diesel models, the molded plastic washer fluid reservoir (1) is integral to the engine coolant overflow bottle (4) located on the right rearward facing surface of the engine cooling module shroud in the right front corner of the engine compartment. On SRT10 and diesel models, the molded plastic washer fluid reservoir is separate from the engine coolant overflow bottle and is mounted on the rearward facing surface of the left vertical member of the radiator support in the engine compartment. These reservoirs are constructed of a translucent plastic that allows the fluid level to be inspected without removing the reservoir caps. A bright yellow plastic filler cap (2) with a rubber seal snaps over the open end of the washer reservoir filler neck and can be easily distinguished from the coolant overflow bottle cap (3) by an International Control and Display Symbol icon for Windshield Washer and the text Washer Fluid Only molded into it. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just behind the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. Except on SRT10 and diesel models, the washer reservoir is secured to the cooling module radiator shroud with two integral tabs at the bottom, and through two integral mounting brackets with two screws at the top. The two bottom tabs are inserted into two slots near the bottom of the shroud, while the two screws secure the mounting brackets to integral mounting points near the top of the shroud. On SRT10 and diesel models, the washer reservoir is secured with two screws through integral mounting brackets to the left vertical member of the radiator support. There are separate, dedicated holes on the lower rearward facing side of either reservoir provided for the mounting of the washer/pump motor unit (6) and the washer fluid level switch (5). A snap post receptacle for the washer pump and a routing trough for the washer hose are molded into both reservoirs to allow for mounting of the washer pump/ motor unit without the use of fasteners. Except on SRT10 and diesel models, the washer reservoir is serviced only as a unit with the engine coolant reserve bottle. A washer reservoir cannot be repaired and, if faulty or damaged, the unit must be replaced. The washer pump/motor unit, the washer fluid level switch, their rubber grommet seals, as well as the reservoir filler cap are each available for individual service replacement. The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted just above the washer pump inlet nipple in the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer system will no longer operate. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 9218 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the coolant overflow hose (3) from the nipple on the radiator filler neck. It is not necessary to open or drain the engine cooling system. 3. Disconnect the reservoir washer hose (4) from the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir into a clean container for reuse. 4. Disconnect the right headlamp and dash wire harness connector from the washer fluid level switch connector receptacle (5). 5. Disconnect the right headlamp and dash wire harness connector from the washer pump/motor unit connector receptacle (7). 6. Remove the two screws (2) that secure the reservoir mounting brackets to the top of the radiator shroud. 7. Grasp the bottom of the washer reservoir (1) firmly with both hands and pull the unit sharply upward to disengage the locking feature on the washer reservoir from the depression in the radiator shroud. 8. Continue lifting the washer reservoir upward far enough to disengage the two mounting tabs at the bottom from the two slots (6) at the bottom of the radiator shroud. 9. Remove the washer reservoir from the right side of the engine compartment. INSTALLATION 1. Position the washer reservoir (1) into the right side of the engine compartment. 2. Align and insert the two mounting tabs at the bottom of the reservoir into the two slots (6) at the bottom of the radiator shroud. 3. Place both hands on the top of the washer reservoir and push the unit downward far enough for the locking feature on the washer reservoir to snap into the depression in the radiator shroud. 4. Install and tighten the two screws (2) that secure the mounting brackets at the top of the reservoir to the mounting provisions at the top of the radiator shroud. Tighten the screws to 7 N.m (60 in. lbs.). 5. Reconnect the right headlamp and dash wire harness connector to the washer pump/motor unit connector receptacle (7). 6. Reconnect the right headlamp and dash wire harness connector to the washer fluid level switch connector receptacle (5). 7. Reconnect the reservoir washer hose (4) to the barbed nipple of the inline fitting at the engine compartment washer hose in the right headlamp and Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Page 9219 dash wire harness. 8. Reconnect the coolant overflow hose (3) to the nipple on the radiator filler neck. 9. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 10. Reconnect the battery negative cable. 11. Check and adjust the coolant level in the coolant overflow bottle as necessary. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation Windshield Washer Spray Nozzle: Description and Operation The fluidic washer nozzles (1) are constructed of molded plastic. Each nozzle has two integral latches (2) and an anti-rotation tab (4) that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice (5) is oriented towards the windshield glass. The washer plumbing fittings (3) for the washer nozzles extend below the cowl plenum cover/grille panel. The cowl plenum cover/grille panel must be removed from the vehicle to access the nozzles for service. The washer nozzles cannot be adjusted or repaired. If faulty or damaged, they must be replaced. The two washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/ motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Page 9223 Windshield Washer Spray Nozzle: Service and Repair REMOVAL 1. Remove both wiper arms from the wiper pivots. 2. Unlatch and open the hood. 3. Remove the cowl plenum cover/grille panel from over the cowl plenum. 4. From the underside of the cowl plenum cover/grille panel (1), disconnect the washer nozzle hose from the barbed nipple (3) of the washer nozzle. 5. From the underside of the cowl plenum cover/grille panel, release the integral latch features (6) of the washer nozzle and push the nozzle out through the mounting hole toward the top side of the cowl plenum cover/grille panel. 6. Remove the washer nozzle from the top of the cowl plenum cover/grille panel. INSTALLATION 1. From the top of the cowl plenum cover/grille panel, position the nipple end of the washer nozzle through the mounting hole and engage the anti-rotation tabs (2 and 4) of the nozzle into the anti-rotation notches in the mounting hole. 2. Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral latch features (6) lock into place on the underside of the cowl plenum cover/grille panel (1). 3. From the underside of the cowl plenum cover/grille panel, reconnect the washer hose to the barbed nipple (3) of the washer nozzle. 4. Reinstall the washer nozzle hose into its routing clips on the underside of the cowl plenum cover/grille panel. 5. Reinstall the cowl plenum cover/grille panel over the cowl plenum. 6. Close and latch the hood. 7. Reinstall both wiper arms onto the wiper pivots. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation Wiper Arm: Description and Operation The wiper arms are the rigid members located between the wiper pivots protruding from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. Both wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arms each have a die cast metal pivot end (3) with a large internally serrated socket formation at one end. A key (4) within the socket formation indexes the wiper arm to a keyway in the pivot shaft to provide wiper alignment, and a spring-loaded latch (5) on the underside of the pivot end locks the unit to the pivot shaft when it is fully installed. The wide end of a tapered, stamped steel channel (8) hinges on and is secured with a hinge pin (6) to the blade end of both the right and left wiper arm pivot ends. One end of a long, rigid, stamped steel strap (2), with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook (1). Concealed within the stamped steel channel, one end of a long spring (7) is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. The right and left wiper arms are unique and are not interchangeable. A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced. The wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The serrated and keyed socket formation in the wiper arm pivot end interlocks with the serrations and keyway on the outer circumference of the wiper pivot shaft, providing positive engagement and alignment of this connection. The latch positively locks the wiper arm to the wiper pivot shaft when the arm is fully installed. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Page 9227 Wiper Arm: Service and Repair REMOVAL 1. Lift the wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot shaft connection. 2. Pull the latch (2) on the pivot end (1) of the wiper arm outward. 3. Using a slight rocking action, disengage and remove the wiper arm pivot end from the wiper pivot shaft. INSTALLATION NOTE: The right and left wiper arms are not interchangeable. The right wiper arm is slightly longer than the left. Be certain that each wiper arm is installed on the proper wiper pivot. 1. Place the wiper arm hinge in its over-center position prior to attempting installation. 2. The wiper arms are indexed to the wiper pivot shafts with integral keys in the wiper arm pivot ends (1) and keyways in the wiper pivot shafts. Align the key of the wiper arm to the keyway on the wiper pivot shaft. 3. Once the wiper blade is aligned, push the pivot end of the wiper arm down firmly and evenly over the wiper pivot shaft until it is fully engaged. When the wiper arm is fully engaged on the wiper pivot, the spring-loaded latch (2) will snap back into place against the wiper arm pivot end. 4. Gently lower the wiper arm until the wiper blade is in position on the windshield glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 9241 Wiper Blade: Description and Operation Each wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws (6) of the superstructure. The right and left wiper blades are 60.00 centimeters (23.62 inches) long, and are interchangeable. They have nonreplaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Page 9242 Wiper Blade: Service and Repair CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. REMOVAL 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm downward (toward the wiper element and away from the wiper arm) and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. INSTALLATION 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement Technical Service Bulletin # J11 Date: 090821 Recall - Windshield Wiper Motor Replacement August 2009 Dealer Service Instructions for: Safety Recall J11 Mopar Windshield Wiper Motor Models 2002-2008 (DR) Dodge Truck (1500 series pickup) 2005-2009 (DH) Dodge Truck (2500 series pickup) 2006-2009 (D1) Dodge Truck (3500 series pickup) 2007-2008 (DC) Dodge Truck (3500 series cab chassis) 2008 (DM) Dodge Truck (4500/5500 series cab chassis) NOTE: This recall applies only to the above vehicles that had the original windshield wiper motor replaced with a Mopar service parts windshield wiper motor. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts windshield wiper motor may have been installed on about 1,000 of the above vehicles. These replacement wiper motors may fail under certain operating conditions. A loss of windshield wipers could limit the driver's visibility and cause a crash without warning. Repair The windshield wiper motor must be inspected. Vehicles equipped with a Mopar service parts windshield wiper motor must have the motor replaced. Parts Information Special Tools No special tools are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9251 Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Remove the right and left wiper arms from the wiper pivots. 2. Open the hood. 3. Disconnect and isolate the negative battery cable(s). 4. Remove the plenum cover sound deadening pad. 5. Remove the plastic cowl plenum cover panel from the cowl plenum to expose the wiper motor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9252 6. Inspect the windshield wiper motor: > If the wiper motor has two rubber mounting bushings (Figure 1), the wiper motor is original and is not involved in this recall. Continue with Step 21 of this procedure. NOTE: If the original wiper motor requires some type of repair, the repair cost is the responsibility of the vehicle owner. > If the windshield wiper motor has one rubber mounting bushing (Figure 2), the wiper motor is a Mopar replacement motor and is involved in this recall. Continue with Step 7 of this procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9253 7. Disconnect the wiper motor electrical connector (Figure 3). 8. Remove the wiper motor linkage arm retaining nut from the wiper motor shaft (Figure 3). 9. Remove the wiper motor linkage arm from the motor shaft. NOTE: Do not disconnect the wiper motor linkage arm from the remaining wiper linkage. 10. Remove the three wiper motor retaining bolts (Figure 4). 11. Remove the wiper motor from the vehicle. 12. Transfer the rubber isolator from the old wiper motor onto the new wiper motor (Figure 4). 13. Discard the old wiper motor. 14. Place the new wiper motor into position. 15. Install the three wiper motor retaining bolts (Figure 4). 16. Tighten the upper wiper motor retaining bolts to 70 in. lbs. (8 N.m). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9254 17. Tighten the lower mounting bolt to 75 in. lbs. (8.5 N.m). 18. Connect the wiper motor electrical connector (Figure 3). 19. Install the wiper motor linkage arm to the wiper motor shaft as shown in Figure 5. NOTE: The arms for the wiper pivots must be pointing downward (forward). 20. Install the wiper motor linkage arm nut and tighten the nut to 204 in.lbs. (23 N.m). 21. Install the plastic cowl plenum cover panel. 22. Install the plenum cover sound deadening pad. 23. Connect the negative battery cable(s) to the negative battery post(s). 24. Close the hood. 25. Install the right and left wiper arms onto the wiper pivots and verify that the wiper arm retaining clips are engaged. 26. Cycle the windshield wipers to verify proper operation and the wiper blade park position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9255 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement Technical Service Bulletin # J11 Date: 090821 Recall - Windshield Wiper Motor Replacement August 2009 Dealer Service Instructions for: Safety Recall J11 Mopar Windshield Wiper Motor Models 2002-2008 (DR) Dodge Truck (1500 series pickup) 2005-2009 (DH) Dodge Truck (2500 series pickup) 2006-2009 (D1) Dodge Truck (3500 series pickup) 2007-2008 (DC) Dodge Truck (3500 series cab chassis) 2008 (DM) Dodge Truck (4500/5500 series cab chassis) NOTE: This recall applies only to the above vehicles that had the original windshield wiper motor replaced with a Mopar service parts windshield wiper motor. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this recall service on these vehicles before retail delivery. Dealers should also perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject During a prior service appointment, a Mopar service parts windshield wiper motor may have been installed on about 1,000 of the above vehicles. These replacement wiper motors may fail under certain operating conditions. A loss of windshield wipers could limit the driver's visibility and cause a crash without warning. Repair The windshield wiper motor must be inspected. Vehicles equipped with a Mopar service parts windshield wiper motor must have the motor replaced. Parts Information Special Tools No special tools are required to perform this service procedure. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record recall service completions and provide dealer payments. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9261 Use the labor operation number and time allowance shown. Add the cost of the recall parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a Chrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure 1. Remove the right and left wiper arms from the wiper pivots. 2. Open the hood. 3. Disconnect and isolate the negative battery cable(s). 4. Remove the plenum cover sound deadening pad. 5. Remove the plastic cowl plenum cover panel from the cowl plenum to expose the wiper motor. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9262 6. Inspect the windshield wiper motor: > If the wiper motor has two rubber mounting bushings (Figure 1), the wiper motor is original and is not involved in this recall. Continue with Step 21 of this procedure. NOTE: If the original wiper motor requires some type of repair, the repair cost is the responsibility of the vehicle owner. > If the windshield wiper motor has one rubber mounting bushing (Figure 2), the wiper motor is a Mopar replacement motor and is involved in this recall. Continue with Step 7 of this procedure. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9263 7. Disconnect the wiper motor electrical connector (Figure 3). 8. Remove the wiper motor linkage arm retaining nut from the wiper motor shaft (Figure 3). 9. Remove the wiper motor linkage arm from the motor shaft. NOTE: Do not disconnect the wiper motor linkage arm from the remaining wiper linkage. 10. Remove the three wiper motor retaining bolts (Figure 4). 11. Remove the wiper motor from the vehicle. 12. Transfer the rubber isolator from the old wiper motor onto the new wiper motor (Figure 4). 13. Discard the old wiper motor. 14. Place the new wiper motor into position. 15. Install the three wiper motor retaining bolts (Figure 4). 16. Tighten the upper wiper motor retaining bolts to 70 in. lbs. (8 N.m). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9264 17. Tighten the lower mounting bolt to 75 in. lbs. (8.5 N.m). 18. Connect the wiper motor electrical connector (Figure 3). 19. Install the wiper motor linkage arm to the wiper motor shaft as shown in Figure 5. NOTE: The arms for the wiper pivots must be pointing downward (forward). 20. Install the wiper motor linkage arm nut and tighten the nut to 204 in.lbs. (23 N.m). 21. Install the plastic cowl plenum cover panel. 22. Install the plenum cover sound deadening pad. 23. Connect the negative battery cable(s) to the negative battery post(s). 24. Close the hood. 25. Install the right and left wiper arms onto the wiper pivots and verify that the wiper arm retaining clips are engaged. 26. Cycle the windshield wipers to verify proper operation and the wiper blade park position. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > J11 > Aug > 09 > Recall - Windshield Wiper Motor Replacement > Page 9265 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9266 Wiper Motor: Locations Left Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9267 Left Side Engine Compartment Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 Figure 1 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9274 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9275 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9276 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9277 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9278 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9279 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9280 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9281 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9282 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9283 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9284 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9285 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export ................................................................................................................... Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9286 Wiper Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9287 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9288 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9289 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9290 Motor - Windshield Wiper Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 9291 Wiper Motor: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage (2) - Two tubular steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. A short pigtail wire and connector connect the wiper motor to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. - Pivots (2) - The two wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 9292 Wiper Motor: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) from the wiper motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Page 9293 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in. lbs.) 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in. lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) to the wiper motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation Wiper Motor Linkage: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage (2) - Two tubular steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. A short pigtail wire and connector connect the wiper motor to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. - Pivots (2) - The two wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 9297 Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) from the wiper motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Description and Operation > Page 9298 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in. lbs.) 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in. lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) to the wiper motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation Wiper Pivot: Description and Operation The wiper module is secured with screws through three rubber grommet-type insulators (5) to the cowl plenum panel. The module is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket - The wiper module bracket consists of a long tubular steel main member (2) that has a die cast pivot bracket (1) at each end to which the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. - Crank Arm (10) - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end. - Linkage (2) - Two tubular steel drive links connect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic socket-type bushing (6) on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm (8) of its respective pivot. The right side drive link sleeve-type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud. - Motor (11) - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has a single rubber insulated mounting ear at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting circuit breaker. A short pigtail wire and connector connect the wiper motor to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. - Pivots (2) - The two wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fastened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings. The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced. The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 9302 Wiper Pivot: Service and Repair REMOVAL 1. Remove both wiper arms (4) from the wiper pivots. 2. Unlatch and open the hood. 3. Disconnect and isolate the battery negative cable. 4. Remove the cowl plenum cover/grille panel (5) from over the cowl plenum (8). 5. Disconnect the left headlamp and dash wire harness connector (7) from the wiper motor pigtail wire connector. 6. Remove the two screws (9) that secure the wiper module (6) to the top of the cowl plenum panel at the pivot brackets. 7. Remove the screw that secures the wiper module to the bottom of the cowl plenum panel. 8. Remove the wiper module from the cowl plenum panel as a unit. INSTALLATION Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Pivot > Component Information > Description and Operation > Page 9303 1. Position the wiper module (6) into the cowl plenum (8) as a unit. 2. Install the two screws (9) that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 8 N.m (75 in. lbs.) 3. Install and tighten the screw that secures the wiper module to the bottom of the cowl plenum panel. Tighten the screw to 8 N.m (75 in. lbs.). 4. Reconnect the left headlamp and dash wire harness connector (7) to the wiper motor pigtail wire connector. 5. Reinstall the cowl plenum cover/grille panel (5) over the cowl plenum. 6. Reconnect the battery negative cable. 7. Close and latch the hood. 8. Reinstall both wiper arms (4) onto the wiper pivots. Dodge Ram 1500 2wd Workshop Manual (Truck V8-5.7L VIN 2 (2006)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Dodge Ram 2006-2008, 1500-5500 all, do not use a wiper relay.