Dodge - Ram 2500 4wd - Workshop Manual - 1998 - 1998 (2)

Factory Workshop Manual Make Dodge Model Ram 2500 4wd Engine and year Truck L6-359 5.9L DSL Turbo VIN D FI (1998) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions Antitheft Relay: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 11 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 13 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 16 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 17 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 18 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 19 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 21 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 22 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 23 Antitheft Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 24 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 25 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation Radio/Stereo Noise Filter Relay: Description and Operation SYSTEM OPERATION Filter, Choke, And Speaker Relay Models equipped with the Infinity premium speaker package use this filter, choke, and speaker relay unit to control battery feed to the two speaker- mounted amplifiers. The filter, choke, and speaker relay unit should be checked if there is no sound output noted from both of the front door speakers and the A-pillar tweeters. The filter, choke, and speaker relay unit is mounted to the lower instrument panel center brace, inboard of the Central Timer Module (CTM) and directly above the 16-way data link connector. The filter, choke, and speaker relay unit can be accessed for service without instrument panel disassembly or removal. The filter, choke, and speaker relay unit cannot be repaired and, if faulty or damaged, the unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation > Page 29 Radio/Stereo Noise Filter Relay: Testing and Inspection The filter, choke, and speaker relay is used to switch power to the individual speaker amplifiers used with the Infinity premium speaker package. The choke and relay are serviced only as a unit. If the front door speakers lack bass or low frequency response, while no sound is noted at the Infinity-amplified tweeters in the A-pillar garnish mouldings, the choke and relay should be considered suspect. However, before replacement make the following checks of the choke and relay circuits. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit as required. 3. Unplug the choke and relay wire harness connector. Check for battery voltage at the fused B(+) circuit cavity of the choke and relay wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. Probe the ground circuit cavity of the choke and relay wire harness connector. Check for continuity to a good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open circuit to ground as required. 5. Turn the ignition switch to the On position and turn the radio on. Check for battery voltage at the radio 12-volt output circuit cavity of the choke and relay wire harness connector. If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Turn the radio and ignition switches to the Off position. Plug in the choke and relay wire harness connector. Check for battery voltage at the amplified speaker (+) circuit cavity of the choke and relay wire harness connector. There should be zero volts. Turn the ignition and radio switches to the On position. There should now be battery voltage. If OK, repair the circuits from the choke and relay wire harness connector to the speaker amplifiers as required. If not OK, replace the faulty choke and relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Radio/Stereo Noise Filter Relay > Component Information > Description and Operation > Page 30 Radio/Stereo Noise Filter Relay: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Filter, Choke And Speaker Relay Remove/Install 2. From the driver side of the vehicle, reach under the instrument panel near the 16-way data link connector and inboard of the ash receiver to unplug the filter, choke, and speaker relay wire harness connector from the instrument panel wire harness. 3. Remove the two screws that secure the filter: choke, and speaker relay mounting bracket to the instrument panel center brace. 4. Remove the filter, choke, and speaker relay unit from under the instrument panel. 5. Reverse the removal procedures to install. Tighten the mounting screws to 2.7 N.m (24 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications WITH RWAL ANTILOCK BRAKES: Mounting Screws .............................................................................................................................................................. 2.5 - 3.5 Nm (22 - 31 inch lbs.) WITH 4-WHEEL ANTILOCK BRAKES: Mounting Screws ................................................................................................................................. ................................ 4 - 4.7 Nm (36 - 42 inch lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > EBC 2 > Page 37 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > EBC 2 Electronic Brake Control Module: Diagrams EBC 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > EBC 2 > Page 40 Electronic Brake Control Module: Diagrams EBC 325 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC Controller Antilock Brake (CAB) The CAB is mounted under the hood, separately from the valve body, and has a microprocessor and circuits that: - monitor the brake switch input to tell whether or not to prepare for possible antilock braking - monitor the wheel speed sensor inputs to determine when a rear wheel is tending to lock up. - operate the integral control unit assembly during antilock braking based on comparing the speed sensor to information programmed in memory - detect ABS system related problems and take diagnostic action The CAB will disable antilock control and set a hard ignition latched trouble code if it detects one of the following conditions with itself: - (71) RAM Read/Write - (72) ROM Checksum - (73) Watchdog Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 43 Electronic Brake Control Module: Description and Operation Kelsey-Hayes EBC 325 Controller Antilock Brake (CAB) The CAB is mounted directly to the hydraulic control unit and includes a microprocessor and six solenoids that control brake pressure during antilock braking. The CAB also has circuits that monitor the following: - Brake switch input is monitored to determine whether or not to prepare for possible antilock braking. - Wheel speed sensors are monitored to determine when a wheel is tending to lock up. The CAB will operate the valves in the ECU to control braking pressure during antilock braking. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 44 Electronic Brake Control Module: Description and Operation With Four Wheel Antilock Brakes CAB/HCU The Controller Antilock Brake (CAB) is mounted on the top of the hydraulic control unit. The CAB operates the ABS system and is separate from other vehicle electrical circuits. CAB voltage source is through the ignition switch in the RUN position. The CAB contains dual microprocessors. A logic block in each microprocessor receives identical sensor signals. These signals are processed and compared simultaneously. The CAB contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in a diagnostic program memory and are accessible with the DRB scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Kelsey-Hayes EBC Controller Antilock Brake (CAB) > Page 45 Electronic Brake Control Module: Description and Operation With Rear Wheel Antilock Brakes GENERAL INFORMATION RWAL Controller Antilock Brake (CAB) The Controller Antilock Brakes (CAB) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The CAB functions are: Perform self-test diagnostics. - Monitors the RWAL brake system for proper operation. - Controls the RWAL valve solenoids. NOTE: If the CAB needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor RAM and ROM are tested. If an error occurs during the test a Diagnostic Trouble Code (DTC) will be set into the RAM memory. However it is possible the DTC will not be stored in memory if the error has occurred in the RAM module were the DTC's are stored. Also it is possible a DTC may not be stored if the error has occurred in the ROM which signals the RAM to store the DTC. CAB INPUTS The CAB continuously monitors the speed of the differential ring gear by monitoring signals generated by the rear wheel speed sensor. The CAB determines a wheel locking tendency when it recognizes the ring gear decelerating too rapidly. The CAB monitors the following inputs to determine when a wheel locking tendency may exists: - Rear Wheel Speed Sensor - Brake Lamp Switch - Brake Warning Lamp Switch - Reset Switch - 4WD Switch (If equipped) CAB OUTPUTS The CAB controls the following outputs for antilock braking and brake warning information: RWAL Valve - ABS Warning Lamp - Brake Warning Lamp Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System Electronic Brake Control Module: Service and Repair Four Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL 1. Disconnect battery negative cable. Harness Connector Locks 2. Push the harness connector locks to release the locks, then remove the connectors from the CAB. Pump Motor Connector 3. Disconnect the pump motor connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 48 Controller Mounting Screws 4. Remove screws attaching CAB to the Hydraulic Control Unit (HCU). 5. Remove the CAB. INSTALLATION 1. Place the CAB onto the HCU. NOTE: Insure the CAB seal is in position before installation. 2. Install the mounting screws and tighten to 4 - 4.7 Nm (36 - 42 inch lbs.). 3. Connect the pump motor harness. 4. Connect the harnesses to the CAB and lock the connectors. 5. Connect battery. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Antilock Brake System > Page 49 Electronic Brake Control Module: Service and Repair Rear Wheel Antilock Brake System NOTE: If the Controller Antilock Brake (CAB) needs to be replaced, the rear axle type and tire revolutions per mile must be programed into the new CAB. REMOVAL CAB Harness Connections 1. Pull up on the CAB harness connector lock release and remove the connector from the controller. 2. Remove the RWAL valve harness connector from the controller. CAB Mounting Screws 3. Remove the controller mounting screws and remove the controller from the mounting bracket. INSTALLATION 1. Position the controller on the bracket and install the mounting screws. Tighten the screws to 2.5 3.5 Nm (22 - 31 inch lbs.). 2. Install the RWAL valve harness connector into the controller. 3. Install the CAB harness connector into the controller and push down on the connector lock. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 54 Blower Motor Relay: Description and Operation Blower Motor Relay The blower motor relay is a International Standards Organization (ISO)-type relay. The relay is a electromechanical device that switches battery current from a fuse in the Power Distribution Center (PDC) directly to the blower motor. The relay is energized when the relay coil is provided a voltage signal by the ignition switch. This arrangement reduces the amount of battery current that must flow through the ignition switch. The blower motor relay control circuit is protected by a fuse located in the junction block. When the relay is de-energized, the blower motor receives no battery current. See Heating and Air Conditioning/Blower Motor/Blower Motor Relay in the Diagnosis and Testing for more information. The blower motor relay is located in the PDC in the engine compartment. Refer to the PDC label for blower motor relay identification and location. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 55 Blower Motor Relay: Testing and Inspection Relay Test Blower Motor Relay The blower motor relay is located in the Power Distribution Center (PDC). Remove the blower motor relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed directly from a fuse in the Power Distribution Center (PDC), and should be hot at all times. Check for battery voltage at the PDC cavity for relay terminal 30. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal cavity (87A) is not used for this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the blower motor. When the relay is energized, terminal 87 is connected to terminal 30 and provides full battery current to the blower motor feed circuit. There should be continuity between the PDC cavity for terminal 87 and the blower motor relay output circuit cavity of the blower motor wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the blower motor as required. 4. The coil battery terminal cavity (86) is connected to the ignition switch. When the ignition switch is placed in the On position, fused ignition switch output is directed from a fuse in the junction block to the relay electromagnetic coil to energize the relay. There should be battery voltage at the PDC cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the junction block fuse as required. 5. The coil ground terminal cavity (85) is connected to ground. This terminal supplies the ground for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 56 Blower Motor Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for blower motor relay identification and location. 4. Unplug the blower motor relay from the PDC. 5. Install the blower motor relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 60 Compressor Clutch Relay: Description and Operation Compressor Clutch Relay The compressor clutch relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (footprint) is different, the current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The compressor clutch relay is a electromechanical device that switches battery current to the compressor clutch coil when the Powertrain Control Module (PCM) grounds the coil side of the relay The PCM responds to inputs from the heater-A/C mode control switch, the low pressure cycling clutch switch, and the high pressure cut-off switch. See Compressor Clutch Relay in the Diagnosis and Testing for more information. The compressor clutch relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for relay identification and location. The compressor clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 61 Compressor Clutch Relay: Testing and Inspection Relay Test Compressor Clutch Relay The compressor clutch relay is located in the Power Distribution Center (PDC). Refer to the PDC label for relay identification and location. Remove the relay from the PDC to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ±5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to fused battery feed. There should be battery voltage at the cavity for relay terminal 30 at all times. If OK, go to Step 2. If not OK, repair the open circuit to the fuse in the PDC as required. 2. The relay normally closed terminal (87A) is not used in this application. Go to Step 3. 3. The relay normally open terminal cavity (87) is connected to the compressor clutch coil. There should be continuity between this cavity and the A/C compressor clutch relay output circuit cavity of the compressor clutch coil wire harness connector. If OK, go to Step 4. If not OK, repair the open circuit as required. 4. The relay coil battery terminal (86) is connected to the fused ignition switch output (run/start) circuit. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On position. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the junction block as required. 5. The coil ground terminal cavity (85) is switched to ground through the Powertrain Control Module (PCM). There should be continuity between this cavity and the A/C compressor clutch relay control circuit cavity of the PCM wire harness connector C (gray) at all times. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 62 Compressor Clutch Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for compressor clutch relay identification and location. 4. Unplug the compressor clutch relay from the PDC. 5. Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device Control Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 68 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 70 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 71 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 72 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 73 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 75 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 76 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 77 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 78 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 79 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 80 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 81 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 Audible Warning Device Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Audible Warning Device Control Module: Connector Views Ctm "A" Connector CTM "B" Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 Audible Warning Device Control Module: Electrical Diagrams Central Timer Module (Part 1 Of 5) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 Central Timer Module (Part 2 Of 5) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 Central Timer Module (Part 3 Of 5) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 Central Timer Module (Part 4 Of 5) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 Central Timer Module (Part 5 Of 5) NOTE: To view sheets referred to in these diagrams, see Complete Body and Chassis Diagrams. See: Diagrams/Electrical Diagrams/Diagrams By Group Number Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 92 Audible Warning Device Control Module: Description and Operation Central Timer Module The Ram Truck utilize a new Central Timer Module (CTM). This system is available in a Base or High line configuration. The Base (IEM) configuration does not communicate on the CCD bus and will not be addressed in this manual. For concerns about the Base CTM or IEM, please refer to the appropriate Service Manual. The CTM will handle most of the electronic timing and chime functions for the systems on the truck. For example: the halo lamp around the key cylinder is timed out after 30 seconds. This is a typical CTM function. The High line CTM provides the following features: ^ Remote Keyless Entry (RKE) ^ Chime ^ Courtesy Lamp controls/Illuminated Entry ^ Power Door Locks ^ Speed Sensitive Intermittent Wipers ^ Enhanced Accident Response ^ Vehicle Theft Security System (VTSS) The new CTM is located on the right side of the steering column behind the kneeblocker on a metal bracket welded to the instrument panel. It contains a white 18-way and a green 14-way connector. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module/Description and Operation Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 93 Audible Warning Device Control Module: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module NOTE: The following tests may not prove conclusive in the diagnosis of the high-line version of the Central Timer Module (CTM). The most reliable, efficient, and accurate means to diagnose the high-line CTM requires the use of a DRB scan tool. 1. Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the Central Timer. Module (CTM) from its mounting bracket to access the CTM wire harness connectors. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device/Central Timer Module Replacement for the procedures. 4. Unplug the wire harness connectors from the CTM. Check the wire harness connectors and the receptacles in the CTM for loose, corroded, or damaged terminals and pins. If OK, go to Step 5. If not OK, repair as required. 5. Probe the ground circuit cavity of the 14-way CTM wire harness connector and check for continuity to a good ground. Repeat the check between the ground circuit cavity of the 18-way CTM wire harness connector and a good ground. In each case, there should be continuity If OK, go to Step 6. If not OK, repair the open circuit(s) to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the 14-way CTM wire harness connector. If OK, go to Step 7. If not OK, repair the open circuit to the junction block as required. 7. Probe the door lock switch output (lock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Lock position. If OK, go to Step 8. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 8. Probe the door lock switch output (unlock) circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as you actuate each power lock switch to the Unlock position. If OK, go to Step 9. If not OK, repair the open circuit from either or both power lock switch(es) to the CTM as required. 9. Disconnect and isolate the battery negative cable. Reinstall the wire harness connectors to the CTM. Connect the battery negative cable. Back-probe the door lock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as either power lock switch is moved to the Lock position. Repeat the test pressing the Lock button of the Remote Keyless Entry (RKE) transmitter. If OK, go to Step 10. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. 10. Back-probe the door unlock driver circuit cavity of the 18-way CTM wire harness connector and check for battery voltage as the power lock switch is moved to the Unlock position. Repeat the test pressing the Unlock button of the RKE transmitter. If OK, see Power Lock Motor in the Diagnosis and Testing. If not OK using the power lock switch, but OK with the RKE transmitter, see Power Lock Switch in the Diagnosis and Testing. If not OK using the RKE transmitter, but OK with the power lock switch, see Remote Keyless Entry Transmitter in the Diagnosis and Testing. If not OK, with the power lock switch or the RKE transmitter, replace the faulty CTM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Diagrams > Page 94 Audible Warning Device Control Module: Service and Repair REMOVAL Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the steering column opening cover and knee blocker from the instrument panel. See Steering Column Opening Cover and Knee Blocker in the Replacement for the procedures. Central Timer Module (Base) Remove/Install Central Timer Module (High-Line) Remove/Install 3. Remove the two screws that secure the Central Timer Module (CTM) to the bracket on the inboard side of the instrument panel steering column opening. 4. Pull the CTM into the instrument panel steering column opening far enough access and unplug the wire harness connector(s). 5. Remove the CTM from the instrument panel. 6. Reverse the removal procedures to install. Tighten the mounting screws to 1.6 N.m (15 in. lbs.). NOTE: If a new high-line Central Timer Module is installed, the programmable features must be enabled and/or disabled to the customer's preferred settings. Use a DRB scan tool and the proper Diagnostic Procedures to perform these operations. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Service and Repair Daytime Running Lamp Control Unit: Service and Repair REMOVAL 1. Release hood latch an open hood. 2. Disengage wire connector from DRLM. 3. Remove screws attaching DRLM to left front inner fender panel. 4. Separate DRLM from fender. INSTALLATION 1. Position DRLM on fender. 2. Install screws attaching DRLM to left front inner fender panel. Daytime Running Lamp Module (DRLM) 3. Engage wire connector to DRLM. 4. Close hood. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation Headlamp Relay: Description and Operation SYSTEM OPERATION The headlamp (or security) relay is a International Standards Organization (ISO) micro-relay. The terminal designations and functions are the same as a conventional ISO relay. However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The headlamp relay is a electromechanical device that switches battery current to the headlamps when the high-line Central Timer Module (CTM) grounds the relay coil. See Headlamp Relay in the Diagnosis and Testing for more information. The headlamp (or security) relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The headlamp relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation > Page 105 Headlamp Relay: Testing and Inspection The headlamp (or security) relay and the horn relay are located in the Power Distribution Center (PDC) in the engine compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Relay Terminals Remove the relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Description and Operation > Page 106 Headlamp Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for headlamp (or security) relay identification and location. 4. Unplug the headlamp relay from the PDC. 5. Install the headlamp relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions Horn Relay: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 112 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 113 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 114 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 115 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 116 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 117 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 118 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 119 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 120 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 121 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 122 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 123 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 124 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 125 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 126 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 127 Horn Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 128 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 129 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 130 Horn Relay: Description and Operation SYSTEM OPERATION The horn relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The horn relay is a electromechanical device that switches battery current to the horn when the horn switch grounds the relay coil. See Horn Relay in the Diagnosis and Testing for more information. The horn relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the PDC until further diagnosis is completed. The horn relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 131 Horn Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module Relay Test Horn Relay The horn relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for horn relay identification and location. Remove the horn relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30,d no continuity between terminals 87 and 30. If OK go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair the open circuit to the PDC fuse as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. This terminal supplies battery voltage to the horn(s). There should be continuity between the cavity for relay terminal 87 and the horn relay output circuit cavity of each horn wire harness connector at all times. If OK, go to Step 4. If not OK, repair the open circuit to the horn(s) as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. It is connected to battery voltage and should be hot at all times. Check for battery voltage at the cavity for relay terminal 86. If OK, go to Step 5. If not OK, repair the open circuit to the fuse in the PDC as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay. It is grounded through the horn switch when the horn switch is depressed. It can also be grounded by the high-line Central Timer Module (CTM) in response to inputs from the Vehicle Theft Security System (VTSS) or the Remote Keyless Entry (RKE) system. Check for continuity to ground at the cavity for relay terminal 85. There should be continuity with the horn switch depressed, and no continuity with the horn switch released. If not OK, see Horn Switch in the Diagnosis and Testing. The headlamp (or security) relay and the horn relay are located in the Power Distribution Center (PDC) in the engine compartment. Each of these relays can be tested as described in the following procedure, however the circuits they are used in do vary. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 132 Relay Terminals Remove the relay from the PDC as described to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, test the relay circuits. If not OK, replace the faulty relay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Diagrams > Page 133 Horn Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC for horn relay identification and location. 4. Unplug the horn relay from the PDC. 5. Install the horn relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions Interior Lighting Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 138 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 139 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 140 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 141 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 142 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 143 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 144 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 145 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 146 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 147 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 148 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 149 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 150 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 151 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 152 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 153 Interior Lighting Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 154 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram Information and Instructions > Page 155 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams Relay Box: Diagrams Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 160 Power Distribution Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 161 Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 162 Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Page 163 Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update Technical Service Bulletin # 08-43-99 Date: 991217 Wiper Module - CTM Mandatory PROM Update NUMBER: 08-43-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: Central Timer Module Software Update When A Wiper Module Is Replaced OVERVIEW: This bulletin involves selectively erasing and reprogramming the Central Timer Module (CTM) with new software (EEPROM changes). MODELS: 1998 - 1999 (BR/BE) Ram Trucks NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY. DISCUSSION: Due to a design change in MOPAR replacement wiper modules, the CTM must be updated with new software in order to allow the wiper module to function properly. This following Repair Procedure must be performed any time the wiper module is replaced. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7025 DIN Power Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2046 OR HIGHER. THE DRB III MUST BE OPERATING AT VERSION LEVEL 30.9 OR HIGHER. POLICY: Reimbursabie within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-22-90 0.2 Hrs. FAILURE CODE: FM - Flash Module CTM Flash With Vehicle Connected to DRBIII and MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) to the DRB III (Scan Tool) with the GPIB cable. Connect the DRB III to the vehicle with the J1962 cable and switch the ignition key to "ON". 3. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 170 6. Select "READ PART NUMBERS FROM VEHICLE" and click "SHOW UPDATES" on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Select the new CTM software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will download software files to the DRB Ill® and program CTM in approximately 30 seconds. 9. When MDS2 status box reads "Check DRB Screen For Important Instructions," proceed with the instructions identified on the DRB III screen. CTM Flash With DRBIII In Disconnected Mode 1. Log onto the MDS2 system. 2. A MDS2 session can be started by either entering the VIN or by selecting the appropriate Year, Model, and Engine. CAUTION: MDS2 SYSTEM SOFTWARE OPERATING AT CIS CD2046 WILL NOT DISPLAY ANY AVAILABLE CTM FLASHES WHEN A SESSION IS STARTED BY SELECTING YEAR, MODEL, AND ENGINE FOR 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). SELECT THE 1998 5.9L 24 VALVE CUMMINS ENGINE IF IT BECOMES NECESSARY TO FLASH A CTM ON A 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). ALL SUBSEQUENT (CIS CD2047 OR HIGHER) MDS2 RELEASES WILL FUNCTION PROPERLY. 3. Connect the DRB III to the MDS2 (Mopar Diagnostic System) with the GPIB cable and the DIN cable. 4. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN 5. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 6. Once the vehicle information has been entered, push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Using the light pen, scroll to the bottom of the list of available flashes and select all available CTM software part numbers, then click DOWNLOAD SOFTWARE TO DRB III. It will take less than one minute to download the software into the DRB III. NOTE: PART NUMBERS LISTED ARE SOFTWARE PART NUMBERS ONLY AND MAY NOT MATCH THE ACTUAL CTM PART NUMBER IDENTIFIED ON THE CTM. IN ADDITION, THE SOFTWARE PART NUMBER WILL NOT MATCH THE SOFTWARE VERSION NUMBER THAT WILL BE IDENTIFIED WHEN USING DRB III "STAND ALONE" MODE TO COMMUNICATE TO THE CTM. 8. Once the software has been downloaded, a dialog box will appear identifying that the download was successful. Select OK. 9. Disconnect the DRB III from the MDS2 and connect the DRB III to the vehicle. 10. Connect the DRB III to the vehicle and switch the ignition key to the RUN position. 11. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 12. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 13. Wait for the "MDS2 diagnostic mode" menu to appear on the DRB III. 14. Use the arrow keys and select option # 2, "PROGRAM VEHICLE CONTROLLERS," from the DRB III menu screen. 15. If the vehicle is equipped with a CTM, the CTM software part number will be displayed on the DRB III. Select the CTM flash software part number. 16. Use the Page FWD key on the DRB III to download the software into the CTM. A status screen will display "UPDATE IN PROGRESS" as the software is downloaded into the CTM. 17. To have the DRB III properly verify the CTM software part number, turn the ignition key to OFF when prompted by DRB III. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 171 18. Turn the ignition key to back to RUN when the prompted by DRB III. The DRB III will then confirm that the download was successful by displaying the message CTM REPROGRAMMING WAS SUCCESSFUL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Locations > Component Locations Central Timer Module: Component Locations The new Central Timer Module (CTM) is located on the right side of the steering column behind the kneeblocker on a metal bracket welded to the instrument panel. It contains a white 18-way and a green 14-way connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Locations > Component Locations > Page 174 Junction Block Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions Central Timer Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 177 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 180 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 181 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 182 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 183 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 184 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 185 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 186 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 187 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 188 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 189 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 190 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 191 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 192 Central Timer Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 193 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 194 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Central Timer Module: Connector Views CENTRAL TIMER MODULE (CTM) Central Timer Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 196 Central Timer Module: Electrical Diagrams Airbag System W/Seatbelt Control Timer Module Airbag System Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 197 Central Timer Module System Central Timer Module (CTM) System Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 198 CTM (1 Of 5) CTM (2 Of 5) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 199 CTM (3 Of 5) CTM (4 Of 5) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 200 CTM (5 Of 5) Power Lock System Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 201 Windshield Wiper System Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information Central Timer Module: Technician Safety Information Technician Safety Information DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system. Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watch bands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. These procedures can be found in General Information Section 9.0 (Specifications) or in service manual procedures. Following these procedures is very important to the safety of individuals performing diagnostic tests. DRBIII Safety Information WARNING: Exceeding the limits of the DRB MultiMate is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits. ^ Follow the vehicle manufacturer's service specifications at all times. ^ Do not use the DRB if it has been damaged. ^ Do not use the test leads if the insulation is damaged or if metal is exposed. ^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. ^ Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. ^ Do not exceed the limits shown in the table below: - FUNCTION IN PUT LIMIT - Volts 0 - 500 peak volts AC - 0-500voltsDC - Ohms (resistance)* 0 - 1.12 megohms - Frequency Measured 0 - 10 kHz - Frequency Generated - Temperature -58-1100° F -50-600° C * Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. ^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. ^ Use caution when measuring voltage above 25v DC or 25v AC. ^ A 1 OA fuse or circuit breaker must protect the circuit being tested. ^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. ^ When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. ^ When measuring current, connect the meter in series with the load. ^ Disconnect the live test lead before disconnecting the common test lead. ^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid measuring error form outside interference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Service Precautions > Technician Safety Information > Page 204 Central Timer Module: Vehicle Damage Warnings Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Servicing Sub-Assemblies Some components of the Powertrain system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System Central Timer Module: Description and Operation Airbag System Airbag System Description Airbag System The Airbag Control Module (ACM) is secured to a bracket on the floor panel transmission tunnel below the instrument panel inside the vehicle. The ACM mounting bracket also serves as the instrument panel center support. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags, for one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Warning: The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Note:Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Air Bag Warning Lamp The airbag warning lamp is the only point at which the customer can observe "symptoms" of a system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. The MIC monitors the airbag warning lamp and seat belt warning lamp during the bulb check for a defective bulb or lamp driver circuit, The MIC tests the airbag lamp during the cluster bulb check and substitutes the seat belt lamp if the airbag lamp is defective. If the airbag lamp is defective the MIC will turn the seat belt light on and off approximately 30 times to warn the driver that the airbag lamp is defective. The lamp status is sent to the ACM continuously via a CCD bus message. The seat belt lamp acts as a backup in the event that the AIRBAG lamp is defective. This information is sent to the ACM continuously via a CCD bus message. Perform the WARNING LAMP BULB OR DRIVER procedure to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not illuminate - warning lamp stays illuminated with no active DTC's Club cab and quad cab models of this vehicle are equipped with a structural seat belt system. The structural seat belt system includes a Seatbelt Control Timer Module (SCTM). The SCTM has a hardwired input to the ACM. If a fault input from the SCTM is detected, or the SCTM is not connected, the ACM sends a message to the instrument cluster on the CCD data bus to turn on the seat belt reminder lamp. See Seat Belt Control Timer Module. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced Driver Airbag Module (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 207 The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. Warning: The airbag module inflator assembly contains sodium azide and potassium nitrate. these materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperature exceeding 93°c (2000 f). Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Passenger Airbag Module (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. The airbag module is secured at the bottom to the steel structural base of the instrument panel above the glove box opening. The airbag door is serviced as a unit with the passenger side airbag module, and includes the two passenger heating and air conditioning panel outlet housings. Following an airbag deployment, the airbag module and the instrument panel assembly must be replaced. Passenger Airbag Disarm Switch A Passenger Airbag Disarm Switch (PADS) located on the instrument panel allows the passenger airbag module to be disarmed when certain child restraint devices are being used in the right front seating position. The PADS is equipped with a key cylinder so that the switch position can only be changed using an ignition key. When the ignition switch is in the On position and the passenger side airbag is disarmed, a Light-Emitting Diode (LED) illuminates an "Off "indicator lamp on the faceplate of the switch. To actuate the PADS switch, insert the ignition key in the switch key cylinder. The PADS key cylinder is then rotated with the ignition key to its clockwise stop (the key cylinder slot will be aligned with the "Off,' Indicator lamp) to disarm the passenger side airbag. When the PADS key cylinder is rotated with the ignition key to its counterclockwise stop (the key cylinder slot will be in a vertical position), the Off indicator lamp will be extinguished and the passenger side airbag module will once again be armed. Note: The key must always be removed from the passenger airbag disarm switch key cylinder after the switch has been used. Never leave a key in the pads key cylinder. The PADS cannot be adjusted or repaired and, if faulty or damaged, the PAD switch must be replaced. Warning: The airbag module inflator assembly contains sodium azide and potassium nitrate. these materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperature exceeding 93°c (2000 f). . Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. The fasteners, screws, and bolts originally used for the airbag system components have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Any time a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the Chrysler Mopar parts catalog. Passenger Airbag Disable Switch (PADS) The passenger side airbag disable switch is located on the instrument panel. To de-activate the passenger side airbag, turn the key actuator switch from the horizontal position to a slanted position (pointing to the "OFF" light indicator), approximately 45 degrees clockwise from the PADS "on" position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 208 Rotating the key actuator switch 45 degrees clockwise, remove the key completely from the switch and verify that the switch actuator hole stays in the new position (45 degrees clockwise from horizontal). The switch is spring loaded to the "on" position. It will return to the "on" position unless you remove the key. When the IGNITION is ON, this procedure will illuminate the OFF@ light indicator on the passenger airbag disable switch. To re-enable the passenger side airbag, reverse the procedure above so that the key switch actuator is returned to a horizontal position. NOTE: Do not turn ignition on with key in switch. Do not turn switch with ignition on. Do not leave key in switch. Do not leave the key in the key actuator under any condition. Airbag Diagnostic Trouble Codes Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. The procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. The seat belt lamp replaces the airbag lamp if the airbag lamp is defective. The seat belt lamp pulses on and off 30 times if the airbag warning lamp is defective. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. The exception is the" Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 209 The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: - ACM ACCELEROMETER ...................................................................................................................................... FIRING CAPACITOR LOW - AECM OUTPUT DRIVER CIRCUIT OPEN ........................................................................................................... LOGIC CAPACITOR LOW - AECM INTERNAL DIAGNOSTIC CODE # 1 .................................................................................................... SAFING SENSOR SHORTED - WARNING LAMP DRIVER ERROR For these codes, refer to the appropriate diagnostic procedure: Cluster Message Mismatch Driver Squib Circuit Open Driver Squib Circuit Shorted Driver Squib Circuit Shorted to Battery Driver Squib Circuit Shorted to Ground Loss of Ignition Run Only Loss of Ignition Run/Start No Cluster CCD Message No CCD Communication Missing or Invalid VIN Passenger Squib Circuit Open Passenger Squib Circuit Shorted Passenger Squib Circuit Shorted to Battery Passenger Squib Circuit Shorted to Ground SCTM Failure SCTM Message Mismatch Warning Lamp Bulb or Driver Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 210 Central Timer Module: Description and Operation Interior Lighting Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 211 Central Timer Module: Description and Operation Bus Failure Message Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+)- & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. The Instrument Cluster (MIC) and Powertrain Controller (PCM) supply termination for the 1998 Ram Trucks. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. The Instrument Cluster (MIC) provides the CCD bus bias for the 1998 Ram Trucks. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 212 Central Timer Module: Description and Operation Central Timer Module Central Timer Module Description SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. It is also sometimes referred to as the Integrated Electronic Module (IEM). The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. Refer to Body and Frame/Locks/Power Locks Systems for more information on the RKE system. Refer to Accessories and Optional Equipment/Anti-Theft/Security Systems for more information on the VTSS. Both versions of the CTM are mounted under the driver side end of the instrument panel, inboard of the instrument panel steering column opening. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device/Central Timer Module Replacement for the service procedures. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). See Wiper System in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp (or security) and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A Panic Mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic mode. - An enhanced accident response feature will unlock both doors, then prevent the power door locks from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle reaches a speed of about 24 kilometers-per-hour (15 miles-perhour) or greater. This feature will also lock the doors if a door is opened, then Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 213 closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the driver side end of the instrument panel, inboard of the instrument panel steering column opening. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device/Central Timer Module Replacement for the service procedures. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Central Timer Module Diagnostic Trouble Codes Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 214 Central Timer Module: Description and Operation Airbag System Description Airbag System The Airbag Control Module (ACM) is secured to a bracket on the floor panel transmission tunnel below the instrument panel inside the vehicle. The ACM mounting bracket also serves as the instrument panel center support. The ACM contains a microprocessor, the impact sensor, and energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags, for one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Warning: The airbag system is a sensitive, complex electromechanical unit. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components you must first disconnect and isolate the battery negative (ground) cable. Then wait two minutes for the system capacitor to discharge before further system service. This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Note:Never strike or kick the airbag control module, as it can damage the impact sensor or affect its calibration. If an airbag control module is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Air Bag Warning Lamp The airbag warning lamp is the only point at which the customer can observe "symptoms" of a system malfunction. Whenever the ignition key is turned to the "run" or "start" position, the MIC performs a lamp check by turning the AIRBAG warning lamp on for 6-8 seconds. If the lamp remains off, it means that the ACM has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted to ground. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. The MIC monitors the airbag warning lamp and seat belt warning lamp during the bulb check for a defective bulb or lamp driver circuit, The MIC tests the airbag lamp during the cluster bulb check and substitutes the seat belt lamp if the airbag lamp is defective. If the airbag lamp is defective the MIC will turn the seat belt light on and off approximately 30 times to warn the driver that the airbag lamp is defective. The lamp status is sent to the ACM continuously via a CCD bus message. The seat belt lamp acts as a backup in the event that the AIRBAG lamp is defective. This information is sent to the ACM continuously via a CCD bus message. Perform the WARNING LAMP BULB OR DRIVER procedure to find the cause of any customer complaint regarding the AIRBAG warning lamp, such as: - warning lamp does not illuminate - warning lamp stays illuminated with no active DTC's Club cab and quad cab models of this vehicle are equipped with a structural seat belt system. The structural seat belt system includes a Seatbelt Control Timer Module (SCTM). The SCTM has a hardwired input to the ACM. If a fault input from the SCTM is detected, or the SCTM is not connected, the ACM sends a message to the instrument cluster on the CCD data bus to turn on the seat belt reminder lamp. See Seat Belt Control Timer Module. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced Driver Airbag Module (DAB) The airbag protective trim cover is the most visible part of the driver side airbag system. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator seals the hole in the airbag cushion so it can discharge the gas it Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 215 produces directly into the cushion when supplied with the proper electrical signal. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split at a predetermined breakout line. Warning: The airbag module inflator assembly contains sodium azide and potassium nitrate. these materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperature exceeding 93°c (2000 f). Clockspring The clockspring is mounted on the steering column behind the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wire harness and the driver side airbag module, the horn switch, and the vehicle speed control switches on vehicles that are so equipped. The clockspring must be properly centered when it is installed on the steering column following any service removal, or it will be damaged. The clockspring cannot be repaired it must be replaced. Passenger Airbag Module (PAB) The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system. Located under the airbag door is the airbag cushion and it's supporting components. The airbag module includes a housing to which the cushion and inflator are attached and sealed. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. The inflator assembly is mounted to the back of the airbag module. The inflator includes a small canister of highly compressed argon gas. The inflator seals the hole in the airbag cushion so it can discharge the compressed gas it contains directly into the cushion when supplied with the proper electrical signal. The airbag door has a living hinge at the top, which is secured to the instrument panel top cover. The door also has predetermined breakout lines concealed beneath its decorative cover. Upon airbag deployment, the airbag door will split at the breakout lines and the door will pivot out of the way. The airbag module is secured at the bottom to the steel structural base of the instrument panel above the glove box opening. The airbag door is serviced as a unit with the passenger side airbag module, and includes the two passenger heating and air conditioning panel outlet housings. Following an airbag deployment, the airbag module and the instrument panel assembly must be replaced. Passenger Airbag Disarm Switch A Passenger Airbag Disarm Switch (PADS) located on the instrument panel allows the passenger airbag module to be disarmed when certain child restraint devices are being used in the right front seating position. The PADS is equipped with a key cylinder so that the switch position can only be changed using an ignition key. When the ignition switch is in the On position and the passenger side airbag is disarmed, a Light-Emitting Diode (LED) illuminates an "Off "indicator lamp on the faceplate of the switch. To actuate the PADS switch, insert the ignition key in the switch key cylinder. The PADS key cylinder is then rotated with the ignition key to its clockwise stop (the key cylinder slot will be aligned with the "Off,' Indicator lamp) to disarm the passenger side airbag. When the PADS key cylinder is rotated with the ignition key to its counterclockwise stop (the key cylinder slot will be in a vertical position), the Off indicator lamp will be extinguished and the passenger side airbag module will once again be armed. Note: The key must always be removed from the passenger airbag disarm switch key cylinder after the switch has been used. Never leave a key in the pads key cylinder. The PADS cannot be adjusted or repaired and, if faulty or damaged, the PAD switch must be replaced. Warning: The airbag module inflator assembly contains sodium azide and potassium nitrate. these materials are poisonous and extremely flammable. Contact with acid, water, or heavy metals may produce harmful and irritating gases (sodium hydroxide is formed in the presence of moisture) or combustible compounds. In addition, the passenger airbag module contains argon gas pressurized to over 2500 psi. Do not attempt to dismantle an airbag module or tamper with its inflator. Do not puncture, incinerate, or bring into contact with electricity. Do not store at temperature exceeding 93°c (2000 f). . Replace airbag system components only with parts specified in the Chrysler Mopar parts catalog. Substitute parts may appear interchangeable, but internal differences may result in inferior occupant protection. The fasteners, screws, and bolts originally used for the airbag system components have special coatings and are specifically designed for the airbag system. They must never be replaced with any substitutes. Any time a new fastener is needed, replace it with the correct fasteners provided in the service package or specified in the Chrysler Mopar parts catalog. Passenger Airbag Disable Switch (PADS) The passenger side airbag disable switch is located on the instrument panel. To de-activate the passenger side airbag, turn the key actuator switch from the horizontal position to a slanted position (pointing to the "OFF" light indicator), approximately 45 degrees clockwise from the PADS "on" position. Rotating the key actuator switch 45 degrees clockwise, remove the key completely from the switch and verify that the switch actuator hole stays in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 216 new position (45 degrees clockwise from horizontal). The switch is spring loaded to the "on" position. It will return to the "on" position unless you remove the key. When the IGNITION is ON, this procedure will illuminate the OFF@ light indicator on the passenger airbag disable switch. To re-enable the passenger side airbag, reverse the procedure above so that the key switch actuator is returned to a horizontal position. NOTE: Do not turn ignition on with key in switch. Do not turn switch with ignition on. Do not leave key in switch. Do not leave the key in the key actuator under any condition. Airbag Diagnostic Trouble Codes Airbag Diagnostic Trouble Codes Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. The procedure begins with AIRBAG TEST 1A - Identifying Airbag System Problems. This will direct you to the specific test(s) that must be performed. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. In certain test procedures within this manual, diagnostic trouble codes are used as a diagnostic tool. Active Codes The code becomes active as soon as the malfunction is detected or key-off, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the airbag control module checks that circuit/function. It is impossible to erase an active code; active codes automatically erase by themselves when the reason for the code has been corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. The seat belt lamp replaces the airbag lamp if the airbag lamp is defective. The seat belt lamp pulses on and off 30 times if the airbag warning lamp is defective. Stored Codes Airbag codes are automatically stored in the ACM's memory as soon as the malfunction is detected. The exception is the" Loss of Ignition Run Only" code which is an active code only. A "stored" code indicates there was an active code present at some time. However, the code currently may not be present as an active code, although another active code could be. When a trouble code occurs, the airbag warning lamp illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored as long as the malfunction exists. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will continue to be a stored code. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. If no obvious problems are found, erase stored codes, and with the ignition "on" wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Airbag Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 217 The airbag control module may report any of the following diagnostic trouble codes. For the following codes, replace the airbag control module (ACM) even if set intermittently: - ACM ACCELEROMETER ...................................................................................................................................... FIRING CAPACITOR LOW - AECM OUTPUT DRIVER CIRCUIT OPEN ........................................................................................................... LOGIC CAPACITOR LOW - AECM INTERNAL DIAGNOSTIC CODE # 1 .................................................................................................... SAFING SENSOR SHORTED - WARNING LAMP DRIVER ERROR For these codes, refer to the appropriate diagnostic procedure: Cluster Message Mismatch Driver Squib Circuit Open Driver Squib Circuit Shorted Driver Squib Circuit Shorted to Battery Driver Squib Circuit Shorted to Ground Loss of Ignition Run Only Loss of Ignition Run/Start No Cluster CCD Message No CCD Communication Missing or Invalid VIN Passenger Squib Circuit Open Passenger Squib Circuit Shorted Passenger Squib Circuit Shorted to Battery Passenger Squib Circuit Shorted to Ground SCTM Failure SCTM Message Mismatch Warning Lamp Bulb or Driver Interior Lighting Interior Lighting The courtesy lights are controlled by the CTM. The door switches are inputs to the CTM and the courtesy lights are outputs. The glove box lamp and the ash receiver lamp (if equipped) are not controlled by the CTM. They are hardwired to individual switches and fuses. The ignition key halo lamp is controlled by the CTM and will remain on for thirty seconds after the door is closed. The highline CTM also provides for illuminated entry option. If the CTM detects an unlock signal from the RKE transmitter, a door disarm switch input or the door jamb switch input, the interior courtesy lights will be turned on. The illuminated entry function is canceled if the CTM senses an ignition "on" condition or the "lock" command from a valid key fob. If a door is left open or the dome lamp switch is left in the "on" position for more than fifteen minutes, the CTM will extinguish the lamps to avoid discharging the battery. If the lamps are turned on by rotation of the headlamp panel dimmer switch, the CTM will not be able to turn them off. Bus Failure Message Bus Failure Messages Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of the bus wires are shorted to ground. Bus (+)- & Bus (-) Shorted Together - The two bus wires are shorted together. No Termination - The bus system has lost connection with all of its terminators. The Instrument Cluster (MIC) and Powertrain Controller (PCM) supply termination for the 1998 Ram Trucks. Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system has lost connection with all modules that provide bias. The Instrument Cluster (MIC) provides the CCD bus bias for the 1998 Ram Trucks. Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 218 Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias. Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not know why. Central Timer Module Description SYSTEM OPERATION Central Timer Module Two versions of the Central Timer Module (CTM) are available on this vehicle, a base version and a high-line version. The base version of the CTM is used on base models of the vehicle. It is also sometimes referred to as the Integrated Electronic Module (IEM). The base version of the CTM combines the functions of a chime/buzzer module, an intermittent wipe module, and an ignition lamp time delay relay in a single unit. The high-line version of the CTM is used on high-line vehicles. The high-line CTM provides all of the functions of the base version CTM, but also is used to control and integrate many of the additional electronic functions and features included on the high-line models. The high-line version of the CTM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection (CCD) data bus network. The CCD data bus network allows the sharing of sensor information. This helps to reduce wire harness complexity, reduce internal controller hardware, and reduce component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. The horn relay is one of the outputs that the high-line CTM can control. The high-line CTM is programmed to energize or de-energize the horn relay in response to certain inputs from the Vehicle Theft Security System (VTSS) and the Remote Keyless Entry (RKE) system. Refer to Body and Frame/Locks/Power Locks Systems for more information on the RKE system. Refer to Accessories and Optional Equipment/Anti-Theft/Security Systems for more information on the VTSS. Both versions of the CTM are mounted under the driver side end of the instrument panel, inboard of the instrument panel steering column opening. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device/Central Timer Module Replacement for the service procedures. For diagnosis of the high-line version of the CTM or the CCD data bus, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Both the base and the high-line versions of the CTM support the intermittent wipe and wipe-afterwash features, but only the high-line CTM supports the speed sensitive intermittent wipe. The intermittent wipe relay is one of the outputs that both the base and the high-line versions of the CTM can control. Each CTM is programmed to energize or de-energize the intermittent wipe relay in response to certain inputs from the windshield wiper and washer switches and from the windshield wiper motor park switch. For the speed sensitive intermittent wipe feature, the high-line CTM also uses vehicle speed messages, which are received on the CCD data bus from the Powertrain Control Module (PCM). See Wiper System in the Diagnosis and Testing for diagnosis of the base version of the CTM. For diagnosis of the high-line version of the CTM or the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. The high-line CTM controls features and functions of the power lock, illuminated entry, and Remote Keyless Entry (RKE) systems. The high-line CTM receives hard-wired inputs from the power lock switches, CCD message inputs from the Powertrain Control Module (PCM) and Airbag Control Module (ACM), and coded radio frequency inputs from the RKE transmitters. In response to those and many other inputs, the internal programming of the CTM sends the proper outputs to control the power lock motors, the headlamp (or security) and horn relays, and the courtesy lamps. Some of the features and functions of the power lock, illuminated entry and RKE systems made possible because of the communication of the CTM on the CCD data bus network include: A door-lock inhibit feature which prevents the power lock system from being energized with a power door lock switch if the key is in the ignition and/or the headlamps are on. However, the locks can still be operated manually, with a key, or energized with the RKE transmitter. - A Panic Mode feature which can provide additional personal security and protection. When the Panic button on the RKE transmitter is depressed the vehicle horn will pulse, the headlights will flash, and the interior lights will illuminate on the vehicle for about three minutes, or until the Panic button is depressed a second time. A vehicle speed of about 24 kilometers-per-hour (15 miles-per-hour) will also cancel the panic mode. - An enhanced accident response feature will unlock both doors, then prevent the power door locks from locking the doors for a predetermined time interval, after receiving a CCD message from the ACM indicating a frontal impact of the vehicle requiring airbag deployment. This feature will also turn on the courtesy lamps ten seconds after receiving the ACM deployment message, if the CCD vehicle speed message from the PCM indicates that the vehicle is not moving. Of course, these responses are dependent upon functional battery power and wiring circuitry following the impact. - Rolling door locks is a programmable feature of the power lock system. This feature will automatically lock all of the doors after the vehicle Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 219 reaches a speed of about 24 kilometers-per-hour (15 miles-perhour) or greater. This feature will also lock the doors if a door is opened, then closed again, at any speed above 24 kilometers-per-hour (15 miles-per-hour). - A programmable feature of the RKE system is the enabling or disabling of the horn chirp following activation of the RKE Lock function. This feature can be enabled or disabled and, if enabled, the horn chirp duration (twenty or forty milliseconds) can be selected. Both versions of the CTM are mounted under the driver side end of the instrument panel, inboard of the instrument panel steering column opening. Refer to Instrument Panel, Gauges and Warning Indicators/Audible Warning Device/Central Timer Module Replacement for the service procedures. The programmable features of the CTM can be enabled or disabled using the DRB scan tool as described in the proper Diagnostic Procedures. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. One of the features that the high-line CTM supports and controls is the Vehicle Theft Security System (VTSS). In the VTSS, the CTM receives hard- wired inputs from the door jamb, door lock cylinder, and ignition switches. The programming in the CTM allows it to process the information from these inputs and send control outputs to energize or de-energize the headlamp (or security) relay, horn relay, and the security lamp. The CTM also sends CCD data bus messages to the Powertrain Control Module (PCM) to control the engine no-run feature of the VTSS. The high-line CTM also contains the receiver and control logic for the power lock and Remote Keyless Entry (RKE) systems, which are integrated into the arming, disarming, and triggering functions of the VTSS. For diagnosis of the high-line version of the CTM or of the CCD data bus, a DRB scan tool and the proper Diagnostic Procedures are recommended. The CTM cannot be repaired and, if faulty or damaged, it must be replaced. Central Timer Module Diagnostic Trouble Codes Central Timer Module Diagnostic Trouble Codes - Door Disarm Switch Failure - Door Lock Switch Failure - Door Unlock Switch Failure - Wiper Park Switch Failure - EEPROM Checksum Failure - Internal ROM Test Failure Chime System Chime System The chime system is built into the CTM. The system also supports an external chime request from the instrument cluster. This feature allows the instrument cluster to request a chime from the CTM for gauge problems and tell tale warnings. The CTM chime functions will have priority over the MIC chime requests. There are two chime rates, Low; 50 chimes per minute for reminders and High; 180 chimes per minute for serious conditions that require immediate attention. The high rate chime sounds when the key is left in the ignition and the driver doors is open or the headlights are left on. The low rate chime sounds for any of the other conditions. There is a variable rate feature that allows the chime to sound continuously for key-in and headlamp warning as long as the door is open. The seat belt warning chime is activated for 4 to 6 seconds, and all other chime conditions will activate the chime once at the same time the warning light on the cluster is illuminated. The chime will sound for the following conditions: High Rate - Key in Ignition Warning ignition off, key in ignition, drivers door open - Ignition off, headlamps on, drivers door open Low Rate - Seat belt warning--6 seconds after key on (6 to 8 chimes) or until belt is buckled - Airbag lamp illuminated (3 times after prove-out) - Anti-lock lamp illuminated (2 chimes after prove-out if equipped) - Check engine lamp illuminated (2 chimes after prove-out) - Check gauges lamp illuminated (2 chimes) - Engine Temp High--when gauge enters red zone (2 chimes) - Low fuel - when fuel level reaches 1/8 tank (2 chimes) - Low washer fluid (2 chimes) - Wait to start (diesel only) (2 chimes) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 220 - Water in fuel (diesel only) (2 chimes) If the ignition switch is turned to the run/start position and the driver's door is closed, then opened, the warning chime is defeated. This allows the doors to be open without the warning chime constantly sounding. The CTM stays in this mode until the ignition switch is turned to the "off' position, then normal function will be restored. For additional information on the Central Timer Module, refer to Powertrain Management / Computers and Control Systems / Body Control Module. See: Diagnostics Diagnostics The CTM is fully addressable with the DRB III and it is the recommended method for diagnosis. The CTM reports 6 Diagnostic Trouble Codes. All of the inputs to the CTM can be read with the DRB and the outputs can be actuated. If the inputs are OK and the outputs can be cycled with the DRB, the problem is usually the Central Timer Module. Enhanced Accident Response (Highline CTM Only) Enhanced Accident Response (High line CTM only) If the Airbag Control Module (ACM) deploys the airbags, a message is transmitted over the CCD bus to the CTM module to unlock the doors. The interior lights will be turned on 10 seconds after getting zero speed message on the CCD bus In addition to unlocking the doors, the lock feature will be disabled for a predetermined amount of time following the deployment. Once the ignition key has been cycled to the "off' position, normal operation will resume. This is a programmable feature. Introduction SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 1998 Ram Truck consists of three modules that communicate over the CCD bus (Chrysler Collision Detection multiplex system). There are three additional modules, two types of Powertrain Control Modules (PCM) and the Controller Anti-Lock Brake (CAB) that are not part of the body system, but do utilize the CCD bus for communication. The CAB also utilizes the bus for diagnostics. The PCM sends and receives messages on the CCD bus, however diagnostics are performed through the Serial Communication Interface or SCI, the same as last year. All of the information about the functioning of all the systems is organized, controlled, and communicated by the CCD bus, which is described in this general information section. Through the CCD bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate module(s). All modules receive all the information transmitted on the bus even though a module may not require all the information to perform it's function. It will only respond to messages addressed to it through a binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. Mechanical Instrument Cluster (MIC) Mechanical Instrument Cluster (MIC) The Ram Truck MIC is available in 2 different versions, low line and high line. The low line cluster has 2 gauges, the highline 4 gauges with twelve warning lamps. The gauges are positioned with information received by the cluster over the CCD bus from the PCM. Some of the warning lamps are hardwired and the cluster using the CCD bus information controls some. The MIC is hardwired to the CTM to provide the warning lamp announcement chimes. There is a self test available for the cluster that will actuate all the gauges at their calibration points. The test will not run if the cluster sees engine RPM or vehicle speed. This test will light all CCD controlled lamps for verification of lamp operation. It also forces the odometer liquid crystal display (LCD) to perform a segment check. The self test routine can be entered by pushing and holding the trip reset button while rotating the ignition key from the "off,' to the "on position. When the work "check" appears release the knob and the test will continue. The cluster will provide bus bias and termination and the engine controller provides a second termination. If the cluster is disconnected the bus will not be biased. The cluster will be serviced as an assembly. There will be limited pans available, bulbs and sockets, the front lens, the trip odometer stem cover and the rear cover assembly. No internal parts of the cluster will be serviced. Normal Operation At key on, the cluster will light the low fuel, seat beat, check gauges, and airbag. As the key is turned farther towards the start position, the check engine, ABS (if equipped) and brake warning lamp will illuminate. The liquid crystal display (LCD) will indicate the mileage stored inside the cluster. If there is a bus failure and the cluster cannot receive distance pulses from the engine controller, the cluster will display the last mileage stored until the ignition is Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 221 turned off. If the cluster is receiving bus messages but is unable to display odometer information because of an internal failure, the odometer display will be blank. Dimming is handled by the potentiometer that controls instrumentation illumination. Lamps (Hardwired) The following lamps are hardwired in the cluster and are not part of the self-test: - Full Time 4WD - Seat Belt - ABS (amber) - High Beam - Left Turn Signal - Right Turn Signal - Security (if equipped) - Low Wash - Wait to Start - O/D Off (if equipped) Lamps (CCD) The cluster via CCD messages controls the following lamps. They are actuated during the self-test procedure. - ABS lamp - Brake Warning - Low Fuel Warning - Internally Controlled by the Cluster not CCD - Airbag - Uptight (if equipped) - Check Engine - Check Gauges - Cruise Control Lamp - Security - Trans Temp - O/D Off (if equipped) - Water in Fuel - Maintenance Required NOTE: The seat belt and low washer switch and brake warning lamp are hardwired to the cluster. The cluster then decides if the lamp should be illuminated. Diagnostics Gauges The instrument cluster will not store any DTCs. Because the engine controller PCM gathers all the gauge information and sends it to the cluster via the bus, it is the controller's responsibility to monitor these inputs and store DTCs for them. For this reason the first item to be checked regarding a gauge problem (except oil pressure) should be the engine controller for any DTCs relating to the gauge in question. There are DTCs associated with all the gauges except for the oil pressure gauge. When diagnosing gauges, the input that is used for the gauge message (fuel level sender for example) must be valid. Because of OBD II requirements, most of the information used for monitoring the OBD II system happens to be the same information used by the controller to formulate the gauge bus messages. OBD II Requirements State that he fuel level sender must be checked for rationality. This includes determining if the sending unit voltage is too high or too low or if the voltage hasn't changed over time. If the PCM has determined that the sender information isn't valid, it will send a diagnostic trouble code. The presence or absence of the fuel level sending code in the PCM is an important factor to determine whether a fuel gauge problem is in the sending unit or the cluster. The same situation is used in all cluster diagnostics related to gauge operation with the exception of the oil pressure gauge. OBD II requirements do not include oil pressure monitoring. Therefore, oil pressure diagnostics would dictate that a mechanical oil pressure gauge be attached to the engine for absolute verification of oil pressure readings. Hard Wired Lamps The cluster contains several hard wired lamps described earlier. These lamps are set up in two configurations. Either the cluster supplies power and ground is supplied by the circuit being monitored or the lamp is supplied ground by the cluster and power comes from a module or other device. Refer to the schematic for the specific details on the lamp in question. Verification of the bulb filament may be required in cases of an inoperative lamp. This will require removal of the cluster and the bulb in question. NOTE: All red warning lamps except the wait to start lamp are light emitting diodes (LED). LED's are not replaceable, if defective the instrument cluster must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 222 CCD Controlled Lamps The cluster contains several CCD controlled lamps as described earlier. These lamps are part of the diagnostic self-test. When entering the self-test mode, operation of these lamps can be observed. If the bulb fails to operate during the self-test and the bulb filament is good, the cluster assembly will need to be replaced. NOTE: A flashing seat belt lamp indicates that the airbag warning lamp is not operating properly. Power Door Lock System Power Door Locks The CTM controls the door lock actuator assemblies to handle locking and unlocking with the key fob or interior switch. There is also a door lock inhibit feature that prevents power locking of the doors if the ignition is off and the key is in the ignition. Automatic or Arousing locks are included as a DRB programmable feature. If the vehicle is moving approximately 15 mph and approximately 10 degrees of throttle opening is seen by the PCM, (the PCM will send this info to the CTM via the CCD bus) indicating acceleration, the CTM will cycle the lock actuators. Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS) RKE/VTSS The highline CTM provides for Remote Keyless Entry (RKE). The base CTM is not able to provide these functions. The presence of this option dictates that the vehicle is equipped with a high line CTM. The VTSS system monitors the doorjamb switches and ignition switch to detect unauthorized entry into the vehicle. Once the vehicle is "armed", any one of these inputs can cause the VTSS system to be tripped. Once tripped, the horn and lights will pulse for 3 minutes and if an attempt is made to start the engine, it will start and stall. If the trigger condition is still present, the lights will continue to flash and return to the "armed" state. The cause of the last 4 alarm triggers is stored by the CTM and may be retrieved by the DRB. The system may be disarmed by either an unlock command from a valid RKE key fob or by using a key in either door. Both front door key cylinders and equipped with disarm switches. There is also a VTSS lamp on the dash that provides information to the driver about the state of the vehicle theft system. The RKE system is placed in the programming model by the DRB. The system will store up to four key fob codes. Through the DRB, programming of one key fob without deleting the others is possible. If the key fob is stolen, all the fob codes stored previously may be erased to provide the owner of the vehicle with an extra sense of security. Seat Belt Control Timer Module Seat Belt Control Timer Module The Seat Belt Control Timer Module (SCTM) is secured to a bracket underneath the front edge of the front seat center cushion. The SCTM mounting bracket also serves as the support for the slide-out rear seat cup holder unit. The SCTM controls the supply of battery current to both of the front seat belt retractor latch solenoids. The SCTM contains an electromechanical Gravity (G)-sensor and an electronic timer circuit. The SCTM monitors the ignition switch state and both door jamb switches through hard-wired inputs. In response to those inputs, the SCTM controls hard-wired outputs to both seat belt retractor latch solenoids. The SCTM also sends diagnostic outputs to the Airbag Control Module (ACM) over a hard-wired fault circuit. The SCTM provides battery current to energize the seat belt retractor latch solenoids whenever the ignition switch is in the On or Accessory position, unless the G-sensor input indicates a vehicle condition that requires the seat belt retractor to be latched. When the seat belt retractor latch solenoids are energized the retractor spools are unlatched, and the seat belt webbing can be extracted from the retractor. When the solenoids are de-energized the retractor spools latch, preventing the seat belt webbing from being extracted further from the retractor. This logic ensures that the seat belts will latch and/or remain latched if battery power is lost during a vehicle collision. The electromechanical G-sensor within the SCTM monitors the rate of vehicle acceleration and acceleration in any horizontal direction. The G-sensor also responds to the horizontal attitude of the vehicle. If the G-sensor monitors a gravity force of greater than about 0.7G in any horizontal direction, or the vehicle is tilted in any direction at an angle of greater than about 45 degrees, the SCTM will sense de-energize (lock) the seat belt retractor latch solenoids. The SCTM electronic timer circuit provides the vehicle occupants with the ability to extract the seat belt webbing from the retractor spool for a time period of about 30 minutes after the ignition switch is turned to the Off position. The electronic timer circuit also monitors the state of the door jamb switches, and unlatches the seat belt retractors after either door jamb switch cycles from open to closed or from closed to open. Each time the SCTM receives an input indicating a change in the state of a monitored switch has occurred, the 30 minutes times starts again. The timer also is used to de-energize the retractor latch solenoids after about 30 minutes, and prevent the battery from being drained while the vehicle is not being driven. The hard wired SCTM output to the ACM is used to indicate whether a fault condition is present in the structural seat belt control system. The ACM monitors the input from the SCTM and sends the proper messages to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to turn the seat belt reminder lamp on or off. If the ACM receives a fault input or does not detect any input from the SCTM, it sets a fault code and sends Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 223 messages to the instrument cluster to turn the lamp on. See Seat Belt Reminder Lamp in the Description and Operation section of Group 8E - Instrument Panel Systems in the Service Manual for more information. The SCTM cannot be repaired. If faulty or damaged, it must be replaced. Seat Belt Control System Test Mode The structural seat belt control system has a test mode feature. This feature allows the seat belt control system to be tested from proper operation while the vehicle is stationary by overriding the normal Seat Belt Control Timer Module (SCTM) control functions. The seat belt system and the airbag system must be tested for proper operation following the service of any seat belt control system or airbag system component. See Airbag Systems in this group for more information on testing of the airbag system. This test mode will confirm the following: - Both door jamb switches and they're input circuits to the SCTM are functional. - The fused B (+), fused ignition switch output (run/acc), and ground circuits to the SCTM are functional. - The SCTM fault circuit to the Airbag Control Module (ACM), the ACM, the Chrysler Collision Detection (CCD) data bus, and the seat belt reminder lamp in the instrument cluster are functional. - Both seat belt retractor latch solenoids and their circuits are functional and can be activated by the SCTM. To initiate the structural seat belt control system test mode, proceed at follows: 1. If the structural seat belt controls system test mode has not been performed previously within the past 72 hours, reset the SCTM be removing the Ignition-Off Draw (IOD) fuse from the junction block, then reinstalling it. 2. Sit in the driver side front seat of the vehicle and close all doors. 3. Push in the cigar lighter. 4. Within five seconds the ignition switch must be cycled On, Off, On, Off, On, Off, and then finally back to On position. Leave the ignition switch in the On position for the remainder of this procedure. This action enters the seat belt control system into its test mode for a maximum of five minutes. After five minutes, the seat belt control system will automatically return to its normal operating mode. 5. The seat belt reminder lamp should light shortly after entering the test mode to confirm that the seat belt control system in the test mode, and that the seat belt control system fault circuit is functional. If the lamp fails to light, use a DRB scan tool and the proper Diagnostic Procedures manual to diagnose the SCTM fault circuit to the ACM, the ACM, and the CCD data bus. 6. Open the driver side front door. Check that both the passenger and driver side outboard,front seat belt retractors are unlatched by slowly pulling the seat belt webbing out of the retractor. If only one retractor is unlatched, the latched retractor and circuit must be diagnosed. See Seat Belt Control System in the appropriate service manual group 8M for more information. If both retractors are latched, see Seat Belt Control Timer Module in the Diagnosis and Testing section of this group. 7. Close the drive side from door. Check that both the passenger and driver side outboard front seat belt retractors are latched by slowly pulling the seat belt webbing out of the retractor. If only one retractor is latched, the unlatched retractor and circuit must be diagnosed. See Seat Belt Retractor Latch Solenoid in the Diagnosis and Testing section of this group. If both retractors are unlatched, see Seat Belt Control Timer Module in the Diagnosis and Testing section of this group. 8. Repeat steps #6 and #7, but open and close the passenger side front door instead of the driver side. 9. Turn the ignition switch to the Off position. This will cause the seat belt control system to exit its test mode and return to normal operation. 10. Turn the ignition switch back to the On position. The seat belt reminder and airbag indicator lamps should turn off shortly after their normal display functions (about six and seven seconds, respectively). If either lamp remains lighted, use a DRB scan tool and the proper Diagnostic Procedures manual to diagnose the SCTM fault circuit to the ACM, the airbag system, the ACM, and the CCD data bus. 11. If the seat belt control system test mode has timed out prior to completion of the tests (about five minutes after the test was initiated), go back to step #2. The SCTM is programmed to consider certain parameters as an indication of a faulty Gravity (G)-sensor. In some peculiar vehicle use situations these parameters may be exceeded, causing the seat belt reminder lamp to illuminate indicating an SCTM fault, and then extinguish for no apparent reason. The following parameters should be considered if an intermittent seat belt reminder lamp illumination complaint is being diagnosed, and the test mode reveals no problems with the structural seat belt control system operation. - If the SCTM monitors ten ignition cycles without input from the G-sensor indicating that the vehicle has accelerated or decelerated sufficiently to require the seat belts to be latched. An ignition cycle is defined as: The ignition switch turned to the On position for at least thirty minutes, followed by the ignition switch being turned to the Off position. The SCTM considers this a G-sensor fault because it would normally be expected that the seat belts would require latching at some point while driving, within ten ignition cycles. The SCTM will discontinue the fault signal and reset the ignition cycle counter to zero as soon as it sees a "normal" G-sensor input. - If the SCTM monitors that the G-sensor input has required the seat belts to remain latched for more that about four seconds. This condition could occur if the vehicle is parted on a steep grade with the ignition switch in the On position, and is considered a G-sensor fault by the SCTM because the duration of the G-sensor input requiring the seat belts to be latched should not normally exceed four seconds. The SCTM Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Description and Operation > Airbag System > Page 224 will discontinue the fault signal as soon as it sees a "normal" G-sensor input Vehicle Communication Vehicle Communication The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires. These wires run from one module to another. They receive and deliver coded information between the modules. The information is coded to identify the message as well as the importance of the message. When there are multiple messages trying to access the CCD bus at one time, the code determines the message that has the higher priority, and is then allowed to access the bus first. The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus plus) and "bus -"(bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5 volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the coded messages, there is a voltage divider network located in the module that supplies bus bias or voltage. Along with the module that supplies bias, some modules provide termination. Bias is the voltage necessary to make the bus operational. At least one point of termination is necessary, some systems use more than one. Some modules are capable of biasing and terminating the bus by themselves. Termination in the circuitry (a 120 ohm resistor placed across the bus) is required to complete the voltage divider network circuit and also provide some electromagnetic protection for the bus. Without termination, voltage on the bus goes to approximately 5 volts on one wire and 0 volts on the other wire. In the 1998 Ram Truck, the instrument cluster supplies bus bias and termination and the PCM supplies an additional point of termination. NOTE: Communication over the bus is essential to the proper operation of the vehicles on-board diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle Communications section of this manual. Wiper System Speed Sensitive Intermittent Wipers The Ram truck equipped with a high line CTM will utilize speed sensitive intermittent wipers. Only a high line CTM will be able to support this feature. A base CTM (IEM) will provide for intermittent wipers without the speed sensitive feature. The low and high speeds are controlled through the wiper stalk switch. The intermittent portion of the wiper control is handled by the CTM through the intermittent wiper relay. When the module detects a decrease in delay time as selected by the driver, an immediate wipe of the windshield takes place and the new delay interval is implemented. This feature is present on both the base and highline CTM. When the vehicle is moving at speeds at or below 10 mph, the delay time ranges from 1 to 36 seconds. When the speed rises above 10 mph, the delay times are cut in half for a range of 1/2 to 18 seconds. The speed signal is provided to the CTM from the PCM over the CCD bus. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes Central Timer Module: Reading and Clearing Diagnostic Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 227 Central Timer Module: Component Tests and General Diagnostics Road Testing A Complaint Vehicle Road Testing a Complaint Vehicle Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB. Vehicle Preparation For Testing Vehicle Preparation for Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Central Timer Module <--> [Body Control Module] > Component Information > Testing and Inspection > Reading and Clearing Diagnostic Trouble Codes > Page 228 Central Timer Module: Scan Tool Testing and Procedures DRB III Does Not Power Up (Blank Screen) DRB III Does Not Power Up (Blank Screen) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connection are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Perform Vehicle Communication TEST 1A DRB III Error Messages and Blank Screen DRB III Error Messages and Blank Screen Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1 800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26Jul93 file: key_iff.cc date: Jul 26 1993 line: 548 err. 0x1 User-Requested COLD boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. Display Is Not Visible Display is Not Visible Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming Powertrain Control Module: Technical Service Bulletins Engine Controls - Generic Engine Module Programming NUMBER: 18-033-04 GROUP: Vehicle Performance DATE: August 20, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD OCTOBER, 2004. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-030-03 REV. A DATED OCTOBER 17, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES 8 ADDITIONAL PART NUMBERS, AN ADDITIONAL MODEL YEAR, AND AN UPDATED REPAIR PROCEDURE. SUBJECT: Generic Cummins Engine Control Module (ECM) Procedure OVERVIEW: This bulletin involves programming a generic Cummins ECM with software. MODELS NOTE: This bulletin applies to Ram trucks equipped with the 5.9L Cummins 24-valve diesel engine (sales code ETC or ETH). DISCUSSION: Mopar(R) is phasing out pre-programmed Cummins Diesel Engine Control Modules (ECM). New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future ECM's will require programming utilizing the DRBIII(R) and TechCONNECT. 1998 1/2 - 2002 modules will cause the "Wait to Start" light to flash, indicating the module has not been programmed. CAUTION: Extreme care must be taken when programming the flash file of a generic ECM. Do not randomly select a flash file. If in doubt, contact the STAR Center for assistance. Installing an incorrect flash file into an ECM can cause severe engine damage. Once a flash file is selected and programmed, the controller cannot be reprogrammed with a different flash file. The module can only be reprogrammed to a more recent version of the same released flash file. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 233 PARTS REQUIRED Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 234 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R) must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine and record the "ECM part number" of the ECM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. On 1998 1/2 - 2003 vehicles, select "Cummins". 2004 and later vehicles, proceed to next step. f. "Module Display" g. Record the "ECM part number" on the repair order for later reference. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 235 NOTE: If the ECM is not operational, the "ECM part number" can be obtained from the label on the controller. For 1998 1/2 - 2002 vehicles, if the label on the controller is not legible, proceed to next step. For 2003 and later vehicles, if the label on the controller is not legible, record the "Reference No." for use later. The "Reference No." is located in the Reference No. box at the top, center of the Engine Data Plate (Fig. 1). Do not use the reference number shown in the figure. The Engine Data Plate is located on the intake side of the breather cover or affixed to the APPS bracket. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to Step # 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with Step # 6. This information is available from: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the District Manager. CAUTION: Failure to install the SKIM pin number into the module after flashing the Cummins ECM will cause a start and stall condition. 6. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 7. If the old "ECM part number" is known, or for 2003 and later vehicles, proceed to Step # 14. On 1998 1/2 - 2002 vehicles, if the old "ECM part number" is not known, proceed to next step. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 236 8. On DealerCONNECT select the "Service" tab. 9. Select "Vehicle Information Plus". 10. Select "Single VIN Inquiry". 11. Manually enter the VIN and mileage and select "Enter". 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option" window, identify and record: a. Engine (sales code and description). b. Emissions (Federal or California) c. Transmission (Automatic, 5-speed manual, etc.). NOTE: When reprogramming a Cummins ECM be sure to do the following; ^ Download the flash file from TechCONNECT to the DRBIII(R) with the DRBIII(R) disconnected from the vehicle. ^ Download the flash file from the DRBIII(R) to the vehicle with the DRBIII(R) disconnected from TechCONNECT. 14. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. Enter the old Cummins "ECM part number" obtained from the DRBIII(R) in Step # 2 into the "Parts Criteria" window. 16. Select "Show Updates". 17. Highlight the proper flash file from the list: a. If the old "ECM part number" is known, highlight the flash file listed, based on the old "ECM part number" recorded earlier Step # 2. b. For 1998 1/2 - 2002, if the old "ECM part number" is not known, highlight the correct flash file based on the information that was recorded from "Vehicle Options" Step # 13. c. For 2003 and later, if the old part number is not known, highlight the proper flash file based on the Reference No. located in the "Ref. No." box, at the top, center of the Engine Data Plate (Fig. 1). 18. Select the "DRBIII" radio button which is next to the "Download/Update" button. 19. Select the "Download/Update" button. 20. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to the next step. 21. Disconnect the DRBIII(R) from TechCONNECT. 22. Connect the DRBIII(R) to the vehicle. 23. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. 24. If the vehicle is equipped with SKIM, proceed to Step # 25. If the vehicle is not equipped with SKIM, proceed to Step # 26. 25. On vehicles equipped with SKIM, transfer the VIN and Security Key information from the SKIM to the ECM. Using the DRBIII(R) select: a. "DRBIII Standalone" Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 237 b. "1998 - 2005 Diagnostics" c. "All" d. "TheftAlarm" e. "SKIM" f. "Miscellaneous" g. "Cummins ECM Replaced" h. Follow the directions on the DRBIII(R) screen. When the process is complete, proceed to Step # 27. 26. On vehicles not equipped with SKIM, manually enter the VIN in the ECM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2005 Diagnostics" c. "All" d. "Engine" e. "Cummins Controller (ECM/ENGINE)" f. "Miscellaneous" g. "CM84X Check VIN" h. Follow the directions on the DRBIII(R) screen. When the process is complete, proceed to next step. NOTE: Due to the Cummins controller programming procedure, a DTC may be set in other modules (PCM, TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 27. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 2). POLICY: Reimbursable within the provisions of the warranty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 238 TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 239 Powertrain Control Module: Technical Service Bulletins Engine Controls/Charging System - Manual Updates NUMBER: 26-08-99F GROUP: Miscellaneous DATE: August, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998-2.5L, 3.9L, 5.2L, 5.9L, 8.0 SFI/Mechanically Injected Diesel Diagnostic Manual Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revisions to the Charging System Low Test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 240 71 Revision to the 5.2/5.9L PCM Wiring Schematic Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - Generic Engine Module Programming > Page 241 744 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical Service Bulletins > Page 242 Powertrain Control Module: Locations PCM The Powertrain Control Module (PCM) is located in the right-rear side of the engine compartment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions Powertrain Control Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 245 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 246 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 248 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 249 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 250 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 251 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 252 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 253 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 254 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 255 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 256 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 257 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 258 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 259 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 260 Powertrain Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 261 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 262 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 263 Powertrain Control Module: Connector Views Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 264 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 265 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 266 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 267 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 268 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 270 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 271 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 272 Powertrain Control Module: Description and Operation SYSTEM OPERATION Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is located in the engine compartment. NOTE: On 3.9L/5.2L/5.9L engines, base ignition timing by rotation of distributor is not adjustable. The PCM opens and closes the ignition coil ground circuit (or circuits) to operate the ignition coil (or coil packs). This is done to adjust ignition timing, both initial (base) and advance, and for changing engine operating conditions. The amount of electronic spark advance provided by the PCM is determined by five input factors: engine coolant temperature, engine rpm, intake manifold temperature, manifold absolute pressure and throttle position. The speed control electronic control circuitry is integrated into the Powertrain Control Module (PCM). The PCM is located in the engine compartment. The PCM speed control functions are monitored by the On-Board Diagnostics (OBD). All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for certain failures it detects. See On-Board Diagnostic Test For Speed Control System for more information. The PCM cannot be repaired and must be replaced if faulty. Transmission Control The PCM controls operation of the converter clutch, overdrive clutch, and governor pressure solenoid. The control module determines transmission shift points based on input signals from the transmission thermistor, transmission output shaft speed sensor, crankshaft position sensor, vehicle speed sensor, throttle position sensor, and battery temperature sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Diagrams > Page 273 Powertrain Control Module: Service and Repair IMPORTANT NOTE: If the Powertrain Control Module (PCM) has been changed and the correct VIN and mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data must be updated to enable starting. For ABS and Air Bag systems: ACTION: 1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules. For SKIM theft alarm: ACTION: 1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in secured access mode, by using the appropriate PIN code for this vehicle. 3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fuel Shutdown Relay, Fuel Heater Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 277 Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 278 Fuel Shutdown Relay Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 279 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 280 Automatic Shut Down (ASD) Relay: Testing and Inspection To perform a complete test of this relay and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 281 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. Repair as necessary before installing relay 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Description and Operation Fuel Shut-off Solenoid Relay: Description and Operation Fuel Heater Relay OPERATION Voltage to operate the fuel shutdown (shut-off) solenoid is supplied from the ignition switch and through the fuel shutdown solenoid relay. CIRCUIT OPERATION When the engine starter motor relay energizes, its contacts close and connect circuit A2 from fuse 2 in the Power Distribution Center (PDC) to circuit T40. Circuit T40 supplies battery voltage to the engine starter motor solenoid and to the coil side of the fuel shut down relay Circuit Z12 provides ground for the coil side of the relay. Circuit A18 from the Power Distribution Center (PDC) supplies battery voltage to the contact side of the fuel shut down relay. When voltage is present on circuit T40, the relay energizes and its contacts close to connect circuits A18 and A123. Circuit A123 supplies power to one of the two coils in the fuel shut down solenoid. When circuit A123 energizes, the fuel shut down solenoid raises the injection pump shut down lever to the RUN position. When the ignition switch is released to the RUN position, it connects circuit A1 from fuse 3 in the PDC to circuit A21. Circuit A21 powers circuit F18 through fuse 9 in the fuse block. Circuit F18 supplies battery voltage to the second coil in the fuel shut down lever. When Circuit F18 energizes, the fuel shut down solenoid holds the injection pump shut down lever in the RUN position. Circuit Z12 provides ground for the fuel shut down solenoid. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Shut-off Solenoid Relay > Component Information > Description and Operation > Page 286 Fuel Shut-off Solenoid Relay: Service and Repair The fuel shutdown solenoid relay is located in the engine compartment near the brake master cylinder. REMOVAL 1. Disconnect both negative battery cables at both batteries. 2. Disconnect the electrical connector at the relay. 3. Remove the relay from the mounting bracket. INSTALLATION 1. Check the terminals within connector for damage or corrosion. - Also check pin height of terminals within connector. - Pin heights should be the same. - Repair as necessary before connecting relay. 2. Install the relay to the mounting bracket. 3. Connect the electrical connector. 4. Connect battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations Air Intake Heater Relay #2 Output, Battery Holder, Air Intake Heater Relay #1 Output, Heater Relay #2, Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 290 Intake Air Heater Relay: Testing and Inspection To test the intake manifold air heater, refer to the Intake Manifold Air Heater Test. To test the intake manifold air heater relays, refer to the following: 1. Disconnect both negative battery cables at both batteries. 2. Disconnect the four small relay trigger wires at both relays. Note position of wires before removal. 3. Disconnect the four large cables at each of the relay terminals (four nuts). Note position of cables before removal. 4. Attach an ohmmeter across two of the large studs on one of the relays. 5. Attach a jumper wire (+ and -) to each of the small terminals on one of the relays. Polarity is not important. 6. Momentarily touch the jumper wires to the vehicle battery (+ and -). The relay should click and the ohmmeter should show a closed circuit across the large terminals. If not, replace relay and bracket assembly 7. Repeat the same test on the opposite relay 8. After testing and repairing, connect battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Intake Air Heater Relay > Component Information > Locations > Page 291 Intake Air Heater Relay: Service and Repair Intake Manifold Air Heater Relays REMOVAL The mounting bracket and both relays are replaced as an assembly. 1. Disconnect both negative battery cables at both batteries. 2. Disconnect the four relay trigger wires at both relays. Note the position of wiring before removing. 3. Lift the four rubber shields from the four cables. 4. Remove the four nuts at the cable connectors. Note the position of wiring before removing. 5. Remove the three relay mounting bracket bolts and remove relay assembly. INSTALLATION 1. Install the relay assembly to the inner fender. Tighten mounting bolts to 4.5 Nm (40 in lb) torque. 2. Connect the eight electrical connectors to the relays. 3. Connect the battery cables to both batteries. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations Automatic Shut Down (ASD) Relay: Locations Fuel Shutdown Relay, Fuel Heater Relay Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 295 Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 296 Fuel Shutdown Relay Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 297 Automatic Shut Down (ASD) Relay: Description and Operation SYSTEM OPERATION As one of its functions, the ASD relay will supply battery voltage to the ignition coil. The ground circuit for the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 298 Automatic Shut Down (ASD) Relay: Testing and Inspection To perform a complete test of this relay and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 299 Automatic Shut Down (ASD) Relay: Service and Repair Power Distribution Center The Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). The PDC is located in the engine compartment. Refer to label on PDC cover for relay location. REMOVAL 1. Remove the PDC cover. 2. Remove the relay by lifting straight up. INSTALLATION 1. Check condition of relay terminals at PDC for corrosion or damage. Also check the heights of relay terminal pins at PDC. Pin height should be same for all pins. Repair as necessary before installing relay 2. Push the relay into the connector. 3. Install the relay cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V002000 > Jan > 99 > Recall 99V002000: Unexpected Air Bag Deployment Air Bag Control Module: Recalls Recall 99V002000: Unexpected Air Bag Deployment Vans and vans used for conversion. If a heavy object impacts the metal casing of the air bag electronic control module (AECM), located under the driver seat, the module could inadvertently deploy the air bags. Unexpected air bag deployment can result in occupant injury. Dealers will replace the AECM with a module that incorporates revised hardware and software on all affected vehicles. Owner notification began February 15, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-32-99 > Oct > 99 > Two Way Radio Intermittent Poor Reception Air Bag Control Module: Customer Interest Two Way Radio - Intermittent Poor Reception NUMBER: 08-32-99 GROUP: Electrical DATE: Oct. 1, 1999 SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a revised Airbag Control Module (ACM). MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM). The following services are within this band range of 30 MHZ to 50 MHZ: ^ Public Service Low Band VHF (30 - 50 MHZ) ^ Six Meter Amateur Radio Band (50 - 54 MHZ) DIAGNOSIS: NOTE: TECHNICAL SERVICE BULLETIN 08-06-99, DATED MARCH 5, 1999, ADDRESSES TWO-WAY RADIO INTERFERENCE FROM THE FUEL PUMP MODULE AND SHOULD BE PERFORMED PRIOR TO PERFORMING THIS TECHNICAL SERVICE BULLETIN. Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, perform the following Repair Procedure. NOTE: THE INTERFERENCE MAY BE INTERMITTENT. IF THE CONDITION IS NOT PRESENT DURING THE DIAGNOSIS, REPEAT THE DIAGNOSIS SEVERAL TIMES TO ATTEMPT TO RE-CREATE THE CONDITION. NOTE: IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: 1 56043128AE Module, Airbag Control REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Replace the ACM with p/n 56043128AE. Refer to the appropriate Ram Truck Service Manual, Group 8M, for information regarding Airbag Control Module Removal And Installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-32-99 > Oct > 99 > Two Way Radio Intermittent Poor Reception > Page 314 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception Air Bag Control Module: All Technical Service Bulletins Two Way Radio - Intermittent Poor Reception NUMBER: 08-32-99 GROUP: Electrical DATE: Oct. 1, 1999 SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a revised Airbag Control Module (ACM). MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM). The following services are within this band range of 30 MHZ to 50 MHZ: ^ Public Service Low Band VHF (30 - 50 MHZ) ^ Six Meter Amateur Radio Band (50 - 54 MHZ) DIAGNOSIS: NOTE: TECHNICAL SERVICE BULLETIN 08-06-99, DATED MARCH 5, 1999, ADDRESSES TWO-WAY RADIO INTERFERENCE FROM THE FUEL PUMP MODULE AND SHOULD BE PERFORMED PRIOR TO PERFORMING THIS TECHNICAL SERVICE BULLETIN. Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, perform the following Repair Procedure. NOTE: THE INTERFERENCE MAY BE INTERMITTENT. IF THE CONDITION IS NOT PRESENT DURING THE DIAGNOSIS, REPEAT THE DIAGNOSIS SEVERAL TIMES TO ATTEMPT TO RE-CREATE THE CONDITION. NOTE: IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: 1 56043128AE Module, Airbag Control REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Replace the ACM with p/n 56043128AE. Refer to the appropriate Ram Truck Service Manual, Group 8M, for information regarding Airbag Control Module Removal And Installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception > Page 320 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Bag Control Module: > NHTSA99V002000 > Jan > 99 > Recall 99V002000: Unexpected Air Bag Deployment Air Bag Control Module: All Technical Service Bulletins Recall 99V002000: Unexpected Air Bag Deployment Vans and vans used for conversion. If a heavy object impacts the metal casing of the air bag electronic control module (AECM), located under the driver seat, the module could inadvertently deploy the air bags. Unexpected air bag deployment can result in occupant injury. Dealers will replace the AECM with a module that incorporates revised hardware and software on all affected vehicles. Owner notification began February 15, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception Air Bag Control Module: All Technical Service Bulletins Two Way Radio - Intermittent Poor Reception NUMBER: 08-32-99 GROUP: Electrical DATE: Oct. 1, 1999 SUBJECT: Radio Interference To/From Two-Way Radio Receivers OVERVIEW: This bulletin involves installing a revised Airbag Control Module (ACM). MODELS: 1998 - 1999 (BR/BE) Ram Truck SYMPTOM/CONDITION: Customers may complain of intermittent poor reception on their two-way radios. NOTE: THIS CONDITION DOES NOT AFFECT THE OPERATION OF ANY AM OR FM BAND RADIO. DISCUSSION: Radio receivers from approximately 30 MHZ to 50 MHZ may be susceptible to Radio Frequency Interference (RFI) from the Airbag Control Module (ACM). The following services are within this band range of 30 MHZ to 50 MHZ: ^ Public Service Low Band VHF (30 - 50 MHZ) ^ Six Meter Amateur Radio Band (50 - 54 MHZ) DIAGNOSIS: NOTE: TECHNICAL SERVICE BULLETIN 08-06-99, DATED MARCH 5, 1999, ADDRESSES TWO-WAY RADIO INTERFERENCE FROM THE FUEL PUMP MODULE AND SHOULD BE PERFORMED PRIOR TO PERFORMING THIS TECHNICAL SERVICE BULLETIN. Turn the ignition key to the RUN position. Operate the two-way radio and monitor for RFI/static/poor reception. If RFI is present with the ignition key in the RUN position, perform the following Repair Procedure. NOTE: THE INTERFERENCE MAY BE INTERMITTENT. IF THE CONDITION IS NOT PRESENT DURING THE DIAGNOSIS, REPEAT THE DIAGNOSIS SEVERAL TIMES TO ATTEMPT TO RE-CREATE THE CONDITION. NOTE: IT IS IMPORTANT TO IDENTIFY WHICH COMPONENTS ARE EMITTING RFI. AFTER A REPAIR HAS BEEN MADE, PERFORM THE DIAGNOSIS AGAIN TO IDENTIFY IF ANY OTHER COMPONENT IS PRODUCING RFI. SOME VEHICLES MAY REQUIRE ADDITIONAL DIAGNOSIS. PARTS REQUIRED: 1 56043128AE Module, Airbag Control REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. 1. Replace the ACM with p/n 56043128AE. Refer to the appropriate Ram Truck Service Manual, Group 8M, for information regarding Airbag Control Module Removal And Installation procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > 08-32-99 > Oct > 99 > Two Way Radio - Intermittent Poor Reception > Page 330 POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-45-09-92 0.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Bag Control Module: > NHTSA99V002000 > Jan > 99 > Recall 99V002000: Unexpected Air Bag Deployment Air Bag Control Module: All Technical Service Bulletins Recall 99V002000: Unexpected Air Bag Deployment Vans and vans used for conversion. If a heavy object impacts the metal casing of the air bag electronic control module (AECM), located under the driver seat, the module could inadvertently deploy the air bags. Unexpected air bag deployment can result in occupant injury. Dealers will replace the AECM with a module that incorporates revised hardware and software on all affected vehicles. Owner notification began February 15, 1999. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 336 Air Bag Control Module: Locations Airbag Control Module (ACM) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 337 Air Bag Control Module: Diagrams Airbag Control Module Connector Airbag Control Module 23-way Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 338 Air Bag Control Module: Description and Operation SYSTEM OPERATION Airbag Control Module The Airbag Control Module (ACM) is secured to a bracket on the floor panel transmission tunnel below the instrument panel inside the vehicle. The ACM mounting bracket also serves as the instrument panel center support. The ACM contains a microprocessor, the impact sensor, and an energy storage capacitor. The microprocessor contains the airbag system logic. The ACM system logic includes On-Board Diagnostics (OBD) capability, and communicates with the instrument cluster circuitry on the Chrysler Collision Detection (CCD) data bus to control the airbag indicator lamp. The microprocessor in the ACM monitors the impact sensor signal and the airbag system electrical circuits to determine the system readiness. If the ACM detects a monitored system fault, it sends messages to the instrument cluster on the CCD data bus to turn on the airbag indicator lamp. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the air- bag system components. Only one impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. The ACM also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact. The purpose of the capacitor is to provide airbag system protection in a severe secondary impact, if the initial impact has damaged or disconnected the battery, but was not severe enough to deploy the airbags. Club cab and quad cab models of this vehicle are equipped with a structural seat belt control system. The structural seat belt control system includes a Seatbelt Control Timer Module (SCTM). The SCTM has a hard wired input to the ACM. If the ACM detects a fault input from the SCTM, or if the ACM does not detect an input from the SCTM, it sends messages to the instrument cluster on the CCD data bus to turn on the seat belt reminder lamp. See Structural Seat Belt Control System for more information. The ACM cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 339 Air Bag Control Module: Service and Repair Airbag Control Module WARNING: THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYSTEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. If the vehicle is equipped with a manual transmission, remove the center console from the floor panel transmission tunnel. Airbag Control Module Trim Cover Remove/Install 3. If the vehicle is equipped with an automatic transmission, remove the two screws that secure the trim cover to the airbag control module mounting bracket, then pull the top of the trim cover rearward to release the two snap clips from the instrument panel support bracket. Airbag Control Module Remove/Install 4. Loosen but do not remove the two screws on the sides that secure the instrument panel support bracket to the airbag control module mounting bracket. 5. Remove the two nuts that secure the support bracket to the stubs on the lower instrument panel. 6. Disengage the wire harness retainer from the hole in the support bracket. 7. Pull the top of the support bracket away from the instrument panel studs and fold it down over the airbag control module until it is laying on the floor panel. 8. Unplug the wire harness connector from the airbag control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Technical Service Bulletins > Page 340 NOTE: Always remove and replace the airbag control module and its mounting bracket as a unit. Replacement modules include a replacement mounting bracket. Do not transfer the module to another mounting bracket. 9. Remove the four screws that secure the mounting bracket to the floor panel transmission tunnel. 10. Remove the airbag control module, the mounting bracket and the support bracket as a unit from the floor panel. 11. When installing the airbag control module, position the unit with the arrow on the module housing pointing forward. 12. Attach the ACM to the floor panel transmission tunnel with the four mounting screws. 13. Reverse the removal procedures to install. Before installing the trim cover or the floor console, be certain that the airbag control module wire harness connector latches are fully engaged and that the connector lock is pushed in. Tighten the mounting hardware as follows: Mounting bracket screws - 14 N.m (125 in. lbs.) - Support bracket nuts - 14 N.m (125 in. lbs.) - Trim cover screws - 2.2 N.m (20 in. lbs.). 14. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 08-14-98 > Mar > 98 > Seat Belt Retractor Clicking,Rattling,or Ratcheting Seat Belt Control Module: Customer Interest Seat Belt Retractor - Clicking,Rattling,or Ratcheting NO: 08-14-98 GROUP: Electrical DATE: Mar. 27, 1998 SUBJECT: Clicking, Rattling, Or Ratcheting Noise Coming From The Seat Belt Retractor MODELS: 1998 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO ALL CLUB CAB VEHICLES (BOTH TWO DOOR CLUB CAB AND QUAD CAB MODELS) BUILT BEFORE MARCH 5, 1998 (MDH 0305XX). DISCUSSION: During normal operation, the seat belt retractor on the vehicles listed above may emit a clicking, rattling, or ratcheting noise. This noise may be caused from a solenoid that is energized and de-energized to operate the retractor spool of the seat belt retractor assembly. The solenoid is controlled by a Seatbelt Control Timer Module (SCTM) which unlocks the retractor when energized. It is normal to have the solenoid energize and de-energize under moderate to heavy acceleration or braking. The noise may be more prevalent if the vehicle is traveling down a rough surfaced road or the vehicle is not traveling on a level surface. If it is presumed that the solenoid is de-energizing prematurely, further diagnosis is required. Refer to the 1998 Ram Truck Service Manual (Publication No. 81-3708108), pages 8M-14 and 8M-15 for additional information. If your diagnosis has determined that the seatbelt retractor solenoid, wiring, and SCTM appear to be functioning normally and the owner feels that the noise occurs too frequently, the SCTM on your vehicle may be too sensitive and should be replaced. The replacement SCTM is p/n 56043003AB. Refer to the 1998 Ram Truck Service Manual (Publication No. 81-3708108), page 8M-17 for information regarding SCTM removal and installation procedures. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-14-98 > Mar > 98 > Seat Belt Retractor - Clicking,Rattling,or Ratcheting Seat Belt Control Module: All Technical Service Bulletins Seat Belt Retractor - Clicking,Rattling,or Ratcheting NO: 08-14-98 GROUP: Electrical DATE: Mar. 27, 1998 SUBJECT: Clicking, Rattling, Or Ratcheting Noise Coming From The Seat Belt Retractor MODELS: 1998 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO ALL CLUB CAB VEHICLES (BOTH TWO DOOR CLUB CAB AND QUAD CAB MODELS) BUILT BEFORE MARCH 5, 1998 (MDH 0305XX). DISCUSSION: During normal operation, the seat belt retractor on the vehicles listed above may emit a clicking, rattling, or ratcheting noise. This noise may be caused from a solenoid that is energized and de-energized to operate the retractor spool of the seat belt retractor assembly. The solenoid is controlled by a Seatbelt Control Timer Module (SCTM) which unlocks the retractor when energized. It is normal to have the solenoid energize and de-energize under moderate to heavy acceleration or braking. The noise may be more prevalent if the vehicle is traveling down a rough surfaced road or the vehicle is not traveling on a level surface. If it is presumed that the solenoid is de-energizing prematurely, further diagnosis is required. Refer to the 1998 Ram Truck Service Manual (Publication No. 81-3708108), pages 8M-14 and 8M-15 for additional information. If your diagnosis has determined that the seatbelt retractor solenoid, wiring, and SCTM appear to be functioning normally and the owner feels that the noise occurs too frequently, the SCTM on your vehicle may be too sensitive and should be replaced. The replacement SCTM is p/n 56043003AB. Refer to the 1998 Ram Truck Service Manual (Publication No. 81-3708108), page 8M-17 for information regarding SCTM removal and installation procedures. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 359 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 360 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 366 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 367 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Component Locations Seat Belt Control Module: Component Locations Seat Tracks And Seat Belt Control Timer Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Component Locations > Page 370 Seat Belt Retractors And Solenoid Assembly Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions Seat Belt Control Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 376 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 377 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 378 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 380 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 381 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 382 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 384 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 385 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 387 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 388 Seat Belt Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 390 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 391 Seat Belt Control Module: Connector Views Seat Belt Control Timer Module (sctm) Seat Main Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Page 392 Seat Belt Control Module: Description and Operation SYSTEM OPERATION The Seatbelt Control Timer Module (SCTM) is secured to a bracket underneath the front edge of the front seat center cushion. The SCTM mounting bracket also serves as the support for the slide-out rear seat cup holder unit. The SCTM controls the supply of battery current to both of the front seat belt retractor latch solenoids. The SCTM contains an electromechanical Gravity (G)-sensor and an electronic timer circuit. The SCTM monitors the ignition switch state and both door jamb switches through hard wired inputs. In response to those inputs, the SCTM controls hard wired outputs to both seat belt retractor latch solenoids. The SCTM also sends diagnostic outputs to the Airbag Control Module (ACM) over a hard wired fault circuit. The SCTM provides battery current to energize the seat belt retractor latch solenoids whenever the ignition switch is in the On or Accessory positions, unless the G-sensor input indicates a vehicle condition that requires the seat belt retractor to be latched. When the seat belt retractor latch solenoids are energized the retractor spools are unlatched, and the seat belt webbing can be extracted from the retractor. When the solenoids are de-energized the retractor spools latch, preventing the seat belt webbing from being extracted further from the retractor. This logic ensures that the seat belts will latch and/or remain latched if battery power is lost during a vehicle collision. The electromechanical G-sensor within the SCTM monitors the rate of vehicle acceleration and deceleration in any horizontal direction. The G-sensor also responds to the horizontal attitude of the vehicle. If the G-sensor monitors a gravity force of greater than about 0.7G in any horizontal direction, or that the vehicle is tilted ill any direction at an angle of greater than about 45 degrees, the SCTM will sense the input from the G-sensor and de-energize the seat belt retractor latch solenoids, which will cause the retractors to latch. The SCTM electronic timer circuit provides the vehicle occupants with the ability to extract the seat belt webbing from the retractor spool for a time period of about 30 minutes after the ignition switch is turned to the Off position. The electronic timer circuit also monitors the state of the door jamb switches, and unlatches the seat belt retractors after either door jamb switch cycles from open to closed or from closed to open. Each time the SCTM receives an input indicating a change in the state of a monitored switch has occurred, the 30 minute timer starts again. The timer also is used to de-energize the retractor latch solenoids after about 30 minutes, and prevent the battery from being drained while the vehicle is not being driven. The hard wired SCTM output to the ACM is used to indicate whether a fault condition is present in the structural seat belt control system. The ACM monitors the input from the SCTM and sends the proper messages to the instrument cluster on the Chrysler Collision Detection (CCD) data bus to turn the seat belt reminder lamp on or off. If the ACM receives a fault input or does not detect any input from the SCTM, it sets a fault code and sends messages to the instrument cluster to turn the lamp on. See Seat Belt Reminder Lamp in the Description and Operation of Instrument Panel Systems for more information. See Airbag Systems for more information about the ACM. For diagnosis of the CCD data bus, the ACM or the ACM input from the SCTM, the use of a DRB scan tool and the proper Diagnostic Procedures are recommended. The SCTM cannot be repaired. If faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Diagrams > Page 393 Seat Belt Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the fasteners that secure the front seat adjusters to the floor panel. Seatbelt Timer Control Module Remove/Install 3. Tilt the seat back and reach under the forward edge of the front seat center cushion to remove the two screws that secure the seatbelt timer control module to the mounting bracket. 4. Lower the seatbelt control timer module from the mounting bracket far enough to access and unplug the wire harness connector. 5. Remove the seatbelt control timer module from under the front seat. 6. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 7. Do not connect the battery negative cable at this time, See Seatbelt Control System Test Mode in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 398 Starter Relay: Description and Operation SYSTEM OPERATION The starter relay is a International Standards Organization (ISO)-type relay. The starter relay is a electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. See Starter Relay in the Diagnosis and Testing for more information. The starter relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The starter relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 399 Starter Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable(s.. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC.. 3. Refer to the label on the PDC for starter relay identification and location. 4. Unplug the starter relay from the PDC. 5. Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable(s.. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: Customer Interest TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 410 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 411 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set Control Module: All Technical Service Bulletins TCM - MIL ON/DTC P1763 Set NUMBER: 21-04-00 GROUP: Transmission DATE: June 3O, 2000 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-07-99, DATED APRIL 30, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE REVISED MODEL YEARS. SUBJECT: Erroneous MIL Illumination For P1763 - Trans. Governor Pressure Sensor Volts Too High OVERVIEW: This bulletin involves selectively erasing and reprogramming the JTEC Powertrain Control Module (PCM) with new software (calibration change 96Cal18, 97Cal18, 98Cal12, and 99Cal14). MODELS: **1996** - 1999 (AB) Ram Van **1996** - 1999 (AN) Dakota **1996** - 1999 (BR/BE) Ram Truck 1998 - 1999 (DN) Durango **1997** - 1999 (TJ) Wrangler **1996** 1999 (XJ) Cherokee **1996** - 1998 (ZJ) Grand Cherokee NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH AN RE SERIES AUTOMATIC TRANSMISSION BUILT BEFORE DECEMBER 18, 1998 (MDH 1218XX). SYMPTOM/CONDITION: Some vehicles may exhibit a MIL illumination with a Diagnostic Trouble Code (DTC) of P1763 - Transmission Governor Pressure Sensor Volts Too High. The vehicle operator may experience slower than normal vehicle accelerations because the transmission may have temporarily entered its third gear "Limp-In" mode as a result of the DTC. The "Limp-In" mode may last until the vehicle owner cycles the ignition key. The technician may not detect a problem with the automatic transmission during a diagnostic test or test drive. The MIL is caused by an increase in hydraulic pressure. The increased hydraulic pressure is the result of a new valve body machining process, which entered into production January 1, 1998. This condition will occur most often with vehicles that were built between January 1, 1998 and December 18, 1998. Vehicles built prior to January 1,1998 may also experience this condition if the valve body or the transmission assembly is replaced with components built after January 1, 1998. DIAGNOSIS: Using the Mopar Diagnostic System (MDS2) and or the Diagnostic Scan Tool (DRB III(R)), with the appropriate Diagnostic Procedures Manual, verify that all engine and transmission systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record them on the repair order and repair as necessary before proceeding further with this bulletin. If no DTC's are present, and the above symptom has been experienced, perform the Repair Procedure. NOTE: WHENEVER A POWERTRAIN (PCM) IS REPLACED DUE TO FAILURE, THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY. PARTS REQUIRED: 1 04669020 Label, Authorized Software Update 1 04275086 Label, Authorized Modification EQUIPMENT REQUIRED: 1 CH6000 Scan Tool (DRB III(R)) 1 CH7035 General Purpose Interface Bus Cable (GPIB) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 417 1 CH7000/7001 J1962 Cable 1 MDS2 NOTE: THE MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. WHEN USING THE MDS2 AND THE DRB III(R), THE SYSTEM MUST BE OPERATING AT CIS CD 2061 OR HIGHER. REPAIR PROCEDURE: 1. Log onto the MDS2 system. 2. Connect the MDS2 and DRB III(R) to the vehicle and switch the ignition key to "ON". 3. Use the arrow keys and select # 2 CONNECT TO MDS2 on the DRB III(R) MAIN MENU SCREEN. 4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU SCREEN. NOTE: ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III(R)" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Select the FLASH tab on the MDS2. 6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2. Press the "OK" button. NOTE: IN ABOVE STEPS # 5 AND/OR # 6, A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS THAT WILL REQUIRE FURTHER INVESTIGATION. 7. Select the new software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of the reprogramming process. NOTE: DUE TO THE PCM REPROGRAMMING PROCEDURE, A DTC MAY BE SET IN OTHER MODULES (EATX, BCM, MIC, SKIM) WITHIN THE VEHICLE, IF SO EQUIPPED. SOME DTC'S MAY CAUSE THE MIL TO ILLUMINATE. ALL DTC'S RELATE TO A LOSS OF COMMUNICATIONS WITH THE MODULE THAT IS BEING REPROGRAMMED. CHECK ALL MODULES, RECORD THE FAULTS, AND ERASE THESE FAULTS PRIOR TO RETURNING THE VEHICLE TO THE CUSTOMER. ERASE ANY FAULTS IN THE PCM ONLY AFTER ALL OTHER MODULES HAVE HAD THEIR FAULTS ERASED. NOTE: THE FOLLOWING STEPS ARE REQUIRED BY LAW. 9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020 (Figure 1). Attach the label to the JTEC PCM and cover the label with the clear plastic overlay. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-04-00 > Jun > 00 > TCM - MIL ON/DTC P1763 Set > Page 418 10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and attach the label near the VECI label (Figure 2). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-42-99 0.5 Hrs. FAILURE CODE: FM - Flash Module Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Page 419 Control Module: Description and Operation This vehicle does not have a Transmission Control Module. Transmission control is accomplished through the Engine Control Module or Powertrain Control Module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions Torque Converter Clutch Relay: Technical Service Bulletins A/T/Ignition - Mis-Fire Test/TC Clutch Service Revisions NUMBER: 26-11-97D GROUP: Miscellaneous DATE: November, 1997 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 AN/BE/BR/DN Powertrain Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the torque convertor clutch solenoid/trans relay test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 424 88 Revision to the multiple mis-fire test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 425 302 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 426 303 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 427 304 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 428 305 Revision to the torque convertor clutch, no RPM drop at lock up test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 429 402 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Torque Converter Clutch Relay > Component Information > Technical Service Bulletins > A/T/Ignition Mis-Fire Test/TC Clutch Service Revisions > Page 430 404 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 434 Power Distribution Center, Transmission Control Relay Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Control Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 440 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 441 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 442 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 443 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 444 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 445 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 446 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 447 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 448 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 449 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 450 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 451 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 452 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 453 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 454 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 455 Windshield Washer Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 456 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 457 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update Technical Service Bulletin # 08-43-99 Date: 991217 Wiper Module - CTM Mandatory PROM Update NUMBER: 08-43-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: Central Timer Module Software Update When A Wiper Module Is Replaced OVERVIEW: This bulletin involves selectively erasing and reprogramming the Central Timer Module (CTM) with new software (EEPROM changes). MODELS: 1998 - 1999 (BR/BE) Ram Trucks NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REMOTE KEYLESS ENTRY. DISCUSSION: Due to a design change in MOPAR replacement wiper modules, the CTM must be updated with new software in order to allow the wiper module to function properly. This following Repair Procedure must be performed any time the wiper module is replaced. EQUIPMENT REQUIRED: 1 CH6OOO Scan Tool (DRB III) 1 CH7035 General Purpose Interface Bus Cable (GPIB) 1 CH7OOO/7001 J1962 Cable 1 CH7025 DIN Power Cable 1 MDS2 NOTE: THE MDS2 AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR. THE MDS2 SYSTEM MUST BE OPERATING AT CIS CD2046 OR HIGHER. THE DRB III MUST BE OPERATING AT VERSION LEVEL 30.9 OR HIGHER. POLICY: Reimbursabie within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 08-19-22-90 0.2 Hrs. FAILURE CODE: FM - Flash Module CTM Flash With Vehicle Connected to DRBIII and MDS2 1. Log onto the MDS2 system. 2. Connect the MDS2 (Mopar Diagnostic System) to the DRB III (Scan Tool) with the GPIB cable. Connect the DRB III to the vehicle with the J1962 cable and switch the ignition key to "ON". 3. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 4. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. NOTE: ONCE MDS2, DRB III, AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE "CANNOT READ VIN FROM DRB III" MESSAGE (ON THE MDS2) WILL BE REPLACED BY THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2 SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO BEGIN SESSION. 5. Push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 462 6. Select "READ PART NUMBERS FROM VEHICLE" and click "SHOW UPDATES" on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Select the new CTM software part number with the light pen and click UPDATE CONTROLLER SOFTWARE. 8. The MDS2 and DRB III will download software files to the DRB Ill® and program CTM in approximately 30 seconds. 9. When MDS2 status box reads "Check DRB Screen For Important Instructions," proceed with the instructions identified on the DRB III screen. CTM Flash With DRBIII In Disconnected Mode 1. Log onto the MDS2 system. 2. A MDS2 session can be started by either entering the VIN or by selecting the appropriate Year, Model, and Engine. CAUTION: MDS2 SYSTEM SOFTWARE OPERATING AT CIS CD2046 WILL NOT DISPLAY ANY AVAILABLE CTM FLASHES WHEN A SESSION IS STARTED BY SELECTING YEAR, MODEL, AND ENGINE FOR 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). SELECT THE 1998 5.9L 24 VALVE CUMMINS ENGINE IF IT BECOMES NECESSARY TO FLASH A CTM ON A 1998 5.9L CUMMINS 16 (12 VALVE ENGINE). ALL SUBSEQUENT (CIS CD2047 OR HIGHER) MDS2 RELEASES WILL FUNCTION PROPERLY. 3. Connect the DRB III to the MDS2 (Mopar Diagnostic System) with the GPIB cable and the DIN cable. 4. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN 5. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 6. Once the vehicle information has been entered, push the FLASH tab on the MDS2. NOTE: A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. 7. Using the light pen, scroll to the bottom of the list of available flashes and select all available CTM software part numbers, then click DOWNLOAD SOFTWARE TO DRB III. It will take less than one minute to download the software into the DRB III. NOTE: PART NUMBERS LISTED ARE SOFTWARE PART NUMBERS ONLY AND MAY NOT MATCH THE ACTUAL CTM PART NUMBER IDENTIFIED ON THE CTM. IN ADDITION, THE SOFTWARE PART NUMBER WILL NOT MATCH THE SOFTWARE VERSION NUMBER THAT WILL BE IDENTIFIED WHEN USING DRB III "STAND ALONE" MODE TO COMMUNICATE TO THE CTM. 8. Once the software has been downloaded, a dialog box will appear identifying that the download was successful. Select OK. 9. Disconnect the DRB III from the MDS2 and connect the DRB III to the vehicle. 10. Connect the DRB III to the vehicle and switch the ignition key to the RUN position. 11. Use the arrow keys and select option # 2, "CONNECT TO MDS1 OR MDS2," on the DRB III MAIN MENU SCREEN. 12. Use the arrow keys and select option # 2, "RUN MDS2 APPLICATION," on the DRB III. 13. Wait for the "MDS2 diagnostic mode" menu to appear on the DRB III. 14. Use the arrow keys and select option # 2, "PROGRAM VEHICLE CONTROLLERS," from the DRB III menu screen. 15. If the vehicle is equipped with a CTM, the CTM software part number will be displayed on the DRB III. Select the CTM flash software part number. 16. Use the Page FWD key on the DRB III to download the software into the CTM. A status screen will display "UPDATE IN PROGRESS" as the software is downloaded into the CTM. 17. To have the DRB III properly verify the CTM software part number, turn the ignition key to OFF when prompted by DRB III. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Technical Service Bulletins > Wiper Module - CTM Mandatory PROM Update > Page 463 18. Turn the ignition key to back to RUN when the prompted by DRB III. The DRB III will then confirm that the download was successful by displaying the message CTM REPROGRAMMING WAS SUCCESSFUL. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Central Timer Module (Base) Central Time Module (Base) Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Central Timer Module (Base) > Page 466 Central Time Module (High-Line) Remove/Install Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions Wiper Control Module: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 469 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 470 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 471 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 472 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 473 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 474 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 475 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 476 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 477 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 478 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 479 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 480 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 481 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 482 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 483 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 484 Wiper Control Module: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 485 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 486 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Power Distribution Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 492 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 493 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 494 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 495 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 496 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 497 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 498 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 499 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 500 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 501 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 502 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 503 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 504 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 505 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 506 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 507 Wiper Relay: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 508 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 509 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 510 Wiper Relay: Description and Operation SYSTEM OPERATION The intermittent wipe relay is a International Standards Organization (ISO) micro-relay The terminal designations and functions are the same as a conventional ISO relay However, the micro-relay terminal orientation (or footprint) is different, current capacity is lower, and the relay case dimensions are smaller than those of the conventional ISO relay. The intermittent wipe relay is a electromechanical device that switches battery current to the windshield wiper motor or wiper motor park switch when the relay coil is grounded by the Central Timer Module (CTM) in response to inputs from the windshield wiper (multi-function) switch. See Intermittent Wipe Relay in the Diagnosis and Testing for more information. The intermittent wipe relay is located in the Power Distribution Center (PDC), in the engine compartment. Refer to the PDC label for relay identification and location. The intermittent wipe relay cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 511 Wiper Relay: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Relays and Modules - Powertrain Management/Relays and Modules - Computers and Control Systems/Central Timer Module Relay Test Intermittent Wipe Relay The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compartment. Refer to the PDC label for intermittent wipe relay identification and location. Remove the intermittent wipe relay from the PDC as described in the Replacement to perform the following tests: 1. A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 2. If not OK, replace the faulty relay. 2. Resistance between terminals 85 and 86 (electromagnet) should be 75 ± 5 ohms. If OK, go to Step 3. If not OK, replace the faulty relay. 3. Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. if OK, see Relay Circuit Test in the Diagnosis and Testing. If not OK, replace the faulty relay. Relay Circuit Test 1. The relay common feed terminal cavity (30) is connected to the wiper (multi-function) switch. There should be continuity between the cavity for relay terminal 30 and the two fused ignition switch output circuit cavities of the multi-function switch wire harness connector at all times. If OK, go to Step 2. If not OK, repair the open circuit(s) to the multi-function switch as required. 2. The relay normally closed terminal (87A) is connected to terminal 30 in the de-energized position. There should be continuity between the cavity for relay terminal 87A and the wiper park switch sense circuit cavities of the wiper motor wire harness connector and the 14-way Central Timer Module (CTM) wire harness connector at all times. If OK, go to Step 3. If not OK, repair the open circuit(s) to the wiper motor and CTM as required. 3. The relay normally open terminal (87) is connected to the common feed terminal (30) in the energized position. There should be battery voltage at the cavity for relay terminal 87 with the ignition switch in the On or Accessory positions. If OK, go to Step 4. If not OK, repair the open circuit to the ignition switch as required. 4. The coil battery terminal (86) is connected to the electromagnet in the relay. There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in the On or Accessory positions. If OK, go to Step 5. If not OK, repair the open circuit to the ignition switch as required. 5. The coil ground terminal (85) is connected to the electromagnet in the relay It is grounded by the CTM to energize the relay and cycle the wiper motor. Check for continuity between the cavity for relay terminal 85 and the intermittent wiper relay control circuit cavity of the 14-way CTM wire harness connector. There should be continuity. If OK, replace the faulty base version CTM; or, use a DRB scan tool and the proper Diagnostic Procedures for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Page 512 Wiper Relay: Service and Repair REMOVAL AND INSTALLATION 1. Disconnect and isolate the battery negative cable. Power Distribution Center 2. Remove the cover from the Power Distribution Center (PDC). 3. Refer to the label on the PDC cover for intermittent wipe relay identification and location. 4. Unplug the intermittent wipe relay from the PDC. 5. Install the intermittent wipe relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place. 6. Install the PDC cover. 7. Connect the battery negative cable. 8. Test the relay operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions Arm/Disarm Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 519 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 520 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 521 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 522 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 523 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 524 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 525 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 526 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 527 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 528 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 529 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 530 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 531 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 532 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 533 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 534 Arm/Disarm Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 535 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Arm/Disarm Switch, Antitheft > Component Information > Diagrams > Diagram Information and Instructions > Page 536 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions Door Sensor/Switch (For Alarm): Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 541 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 542 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 543 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 544 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 545 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 546 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 547 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 548 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 549 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 550 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 551 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 552 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 553 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 554 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 555 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 556 Door Sensor/Switch (For Alarm): Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 557 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door Sensor/Switch (For Alarm) > Component Information > Diagrams > Diagram Information and Instructions > Page 558 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation Lock Cylinder Switch: Description and Operation SYSTEM OPERATION The door lock cylinder switches are mounted to the back of the key lock cylinder inside each door. They are normally-open momentary switches that close to ground only when the lock cylinder is rotated to the unlock position. The door lock cylinder switches cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Description and Operation > Page 562 Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door outside latch handle mounting hardware and linkage from the inside of the door. Door Lock Cylinder Switch Remove/Install - Typical 3. From the outside of the door, pull the door outside latch handle out far enough to access the door lock cylinder switch. 4. Disengage the door lock cylinder switch from the back of the lock cylinder. 5. Unplug the door lock cylinder switch wire harness connector. 6. Disengage the retainers that secure the door lock cylinder switch wire harness to the inner door panel. 7. Remove the door lock cylinder switch from the door. 8. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Road Temperature Sensor > Component Information > Locations Ambient Temperature Sensor/Road Temperature Sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 571 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 572 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 573 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 574 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 575 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 576 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 577 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 578 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 579 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 580 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 581 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 582 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 583 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 584 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 585 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 586 Power Door Lock Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 587 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 588 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 589 Power Door Lock Switch: Description and Operation SYSTEM OPERATION The power locks can be controlled by a two-way switch integral to the power window and lock switch and bezel unit on the trim panel of each front door. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. On models with a base version of the Central Timer Module (CTM), the power lock switches are hard-wired to the power lock motors. On models with a high-line version of the CTM, the power lock switch controls the battery feeds to the lock and unlock sense inputs of the high-line CTM. The CTM then relays the correct battery and ground feeds to the power lock motors. The power window and lock switch and bezel unit cannot be repaired and, if faulty or damaged, the entire switch and bezel unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 590 Power Door Lock Switch: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in either or both power window and lock switch and bezel units refer to Windows and Glass/Windows/Power Window Systems for diagnosis. If only one LED in a power window and lock switch and bezel unit is inoperative, replace the faulty switch and bezel unit. 1. Check the fuse in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the Power Distribution Center (PDC) as required. 3. Disconnect and isolate the battery negative cable. Remove the power window and lock switch and bezel unit from the door trim panel. Unplug the wire harness connector from the switch and bezel unit. 4. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the body half of the power window and lock switch and bezel unit wire harness connector. If OK, go to Step 5. If not OK, repair the open circuit to the junction block as required. Power Lock Switch Continuity - Driver Side Power Lock Switch Continuity - Passenger Side 5. Test the power lock switch continuity. See the Power Lock Switch Continuity charts to determine if the continuity is correct in the Neutral, Lock and Unlock switch positions. If OK, repair the door lock switch output (lock and/or unlock) circuit(s) from the body half of the power window and Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 591 lock switch and bezel unit wire harness connector to the power lock motors or the high-line version of the Central Timer Module (CTM) as required. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Page 592 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window And Lock Switch And Bezel Unit Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the retainer that secures the switch bezel to the door trim panel opening. 3. Pull the switch and bezel unit away from the door trim panel opening far enough to access and unplug the wire harness connector. 4. Remove the power window and lock switch and bezel unit from the door trim panel. 5. Reverse the removal procedures to install. When installing the switch and bezel unit to the door trim panel opening, insert the rear of the bezel into the opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation Power Mirror Switch: Description and Operation SYSTEM OPERATION Both the right and left power outside mirrors are controlled by a single multi-function switch unit located on and mounted to the upper flag area of the driver side door trim panel. The switch knob is rotated clockwise (right mirror control), or counterclockwise (left mirror control) to select the mirror to be adjusted. The switch knob is then moved in a joystick fashion to control movement of the selected mirror up, down, right, or left. The power mirror switch cannot be repaired and, if faulty or damaged, it must be replaced. The power switch knob is available for service replacement. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 596 Power Mirror Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Mirror Switch Remove/Install - Typical 2. Pull the control knob rearward to remove it from the power mirror switch stem. 3. Remove the nut that secures the power mirror switch to the driver side front door trim panel. 4. Remove the trim panel from the inside of the driver side front door. 5. Pull the trim panel away from the inner door far enough to access the power mirror switch wire harness connector. 6. Unplug the power mirror switch wire harness connector. 7. Remove the power mirror switch from the back of the door trim panel. 8. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation Power Seat Switch: Description and Operation SYSTEM OPERATION The power seat in standard cab models can be adjusted in six different ways using the power seat switch. The power seat switch for extended cab models (club cab and quad cab) has an additional switch knob for adjusting the power lumbar support. The switch is located on the lower outboard side of the driver side seat cushion on the seat cushion side shield on all models. Refer to the owner's manual in the vehicle glove box for more information on the power seat switch functions and the seat adjusting procedures. The individual switches in the power seat switch module cannot be repaired. If one switch is damaged or faulty, the entire power seat switch module must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 600 Power Seat Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. 2. Remove the power seat switch from the power seat. Power Seat Switch Continuity 3. Use an ohmmeter to test the continuity of the power seat switches in each position. See the Power Seat Switch Continuity chart. If OK, see Power Seat Adjuster and Motors or Power Lumbar Adjuster and Motor in the Diagnosis and Testing. If not OK, replace the faulty power seat switch module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 601 Power Seat Switch: Service and Repair REMOVAL Standard Cab 1. Disconnect and isolate the battery negative cable. Seat Switch and Bezel Remove/Install 2. Remove the two screws that secure the power seat switch and bezel unit to the seat cushion frame. Power Seat Switch Connector Remove 3. Pull the switch and bezel unit out from the seat far enough to access the switch wire harness connector Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 4. Remove the two screws that secure the power seat switch module to the bezel and remove the bezel. 5. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 N.m (20 in. lbs.). Extended Cab 1. Disconnect and isolate the battery negative cable. 2. Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. 3. Pull the recliner lever off of the recliner mechanism release shaft. 4. Remove the three screws that secure the driver side seat cushion side shield to the outboard seat cushion frame. 5. Pull the driver side seat cushion side shield away from the seat cushion frame far enough to access the power seat switch module wire harness connector. 6. Gently pry the locking tabs of the switch away from the wire harness connector and carefully unplug the connector from the power seat switch module. 7. Remove the seat cushion side shield and power seat switch module from the seat as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 602 Power Seat Switch Remove/Install - Typical 8. Remove the two screws that secure the power seat switch to the inside of the seat cushion side shield. 9. Remove the power seat switch from the seat cushion side shield. 10. Reverse the removal procedures to install. Tighten the switch mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Locations > Page 607 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > 4WD Switch > Component Information > Locations > Page 608 4WD Switch: Description and Operation Vehicles equipped with four wheel drive (4WD) have an indicator switch mounted on the front axle assembly. This switch is closed to ground when the transfer case is shifted to four wheel drive mode and the engine is running on some vehicles. While in four wheel drive, the front and rear axles will operate together. With this input, the CAB is able to modify its operation to allow for 4WD operation. Should a need for antilock operation occur while in four wheel drive, the CAB will extend the amount of allowable dump cycles. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Description and Operation Braking Sensor/Switch: Description and Operation An input from this switch prepares the CAB for a possible antilock stop. The antilock system uses an input signal from the brake pedal activated switch. When the driver applies the brake pedal, the circuit voltage is 12 volts. A released brake pedal will close the switch circuit and provide O volts. This signal tells the CAB that the pedal is depressed Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes Wheel Speed Sensor: Specifications Front Bolts 11 ft.lb Rear Bolts 18 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > With Four Wheel Antilock Brakes > Page 616 Wheel Speed Sensor: Specifications Mounting Bolt 18 ft.lb Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 619 Wheel Speed Sensor: Connector Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front Wheel Speed Sensor: Diagrams Front Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Front > Page 622 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes Wheel Speed Sensor: Description and Operation Four Wheel Antilock Brakes The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing. The sensor is a magnet coil that is mounted over a tone wheel front/exciter ring rear with an air gap between them. The sensors measure the wheel speed by monitoring the rotation of the tone wheels front/exciter ring rear. As the teeth of the tone wheels front/exciter ring rear move through the magnetic field of the sensor an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The Controller Antilock Brake (CAB) monitors these signals for changes in wheel deceleration. If the CAB detects a sudden wheel or wheels deceleration within a predetermined amount the CAB will activate the ABS system. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 625 Wheel Speed Sensor: Description and Operation Kelsey-Hayes Antilock Brake Systems The EBC 325 ABS system uses one wheel speed sensor on each front wheel, and one speed sensor mounted in the rear axle for the rear wheels. The RWAL II uses only one speed sensor mounted in the rear axle for the rear wheels. The sensor measures the wheel speed by monitoring a rotating tone wheel. The signal generated by the sensor and tone wheel is transmitted to the CAB. Each sensor has: - a metal tone wheel with teeth on its outside diameter - a magnetic/coil pick-up (speed sensor) that is mounted to a fixed component - an air gap between the tone wheel and the speed sensor assembly As the teeth of the tone wheel move through the magnetic field of the sensor, an AC voltage is generated. This signal frequency increases or decreases proportionally to the speed of the wheel. The CAB monitors this signal to check for a sudden change in single or multiple wheel decelerations. If the deceleration of one or more wheels is not within a predetermined amount, the antilock module takes control. Diagnostically, the coil of wheel speed sensors have different amounts of resistance based upon the sensor type. When measured across the connector two terminals, the resistance should be: AN, DN, BE and BR: 4x4 front sensors 945-1155 ohms AB, AN and DN: 4x2 front sensors 2500-2955 ohms BE and BR: 4x2 front sensors 1000-1250 ohms AB, AN, DN, BE and BR: All rear sensors 1600-2300 ohms NOTE: For all resistance ranges add 30% to the value for extreme heat, subtract 30% for extreme cold.) The rear wheel speed sensor used on all vehicles have the same resistance value, but there are two different sensors. Therefore, it is important to replace the rear wheel speed sensor with the proper part. On a EBC 325 system each front wheel speed is monitored through the speed sensor mounted at the wheel end of the hub. On a EBC 325 and RWAL II system the rear wheel speed is monitored through the speed sensor mounted in the rear axle assembly. The CAB will disable antilock control, illuminate the ABS warning light circuit via COD, and store trouble codes if it detects a problem with any or all of the wheel speed sensors: - incorrect circuit resistance when checked with no vehicle movement - incorrect sensor output during vehicle movement - erratic sensor output during vehicle movement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Description and Operation > Four Wheel Antilock Brakes > Page 626 Wheel Speed Sensor: Description and Operation Rear Wheel Antilock Brakes The rear wheel speed sensor is mounted on the top of the rear axle differential. The sensor converts wheel speed into an electrical signal that is transmitted to the Rear Wheel Anti-Lock (RWAL) control module. Circuits B113 and B114, a pair of twisted wires connect to the sensor and provide signals to the RWAL control module. These circuits also connect to the rolls test connector used only during manufacture of the vehicle. Circuit B113 connects to cavity 14 of the RWAL control module and to circuit B1 of the wheel speed sensor harness. Circuit B114 connects to cavity 13 of the RWAL control module and circuit B2 of the sensor harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement Front REMOVAL 1. Raise and support vehicle. 2. Remove wheel and tire assembly. 3. Disconnect the ABS wheel speed sensor wire from under the hood. Remove sensor wire from the frame and steering knuckle. 4. Remove brake caliper. 5. Remove rotor on models with 5 wheel studs. On models with 8 studs remove rotor hub bearing assembly and separate the rotor from the hub bearing. Wheel Speed Sensor 6. Remove bolt attaching sensor to the hub bearing. 7. Remove sensor and wire. INSTALLATION 1. Install the sensor in the hub bearing and tighten the bolt to 14 Nm (11 ft. lbs.). Use original or replacement sensor bolts only. The bolts are special and must not be substituted. 2. Install the rotor on models with 5 wheel studs. On models with 8 studs install the rotor on the hub bearing and install the assembly on the knuckle. 3. Install sensor wire to the steering knuckle and frame. Connect the wheel speed sensor wire under the hood. 4. Check sensor wire routing. Be sure wire is clear of all chassis components and is not twisted or kinked at any spot. 5. Install brake caliper. 6. Install wheel and tire assemblies. 7. Remove support and lower the vehicle. 8. Apply brakes several times to seat brake shoes and caliper piston. Do not move vehicle until firm brake pedal is obtained. 9. Verify sensor operation with scan tool. With Rear Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 629 Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. With Four Wheel Antilock Brakes REMOVAL 1. Raise vehicle on hoist. 2. Remove brake line mounting nut and remove the brake line from the sensor stud. Rear Speed Sensor Mounting 3. Remove mounting stud from the sensor and shield. 4. Remove sensor and shield from differential housing. 5. Disconnect sensor wire harness and remove sensor. INSTALLATION 1. Connect harness to sensor. Be sure seal is securely in place between sensor and wiring connector. 2. Install 0-ring on sensor (if removed). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 630 3. Insert sensor in differential housing. 4. Install sensor shield. 5. Install the sensor mounting stud and tighten to 24 Nm (18 ft. lbs.). 6. Install the brake line on the sensor stud and install the nut. 7. Lower vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 631 Wheel Speed Sensor: Service and Repair Tone Wheel Replacement Front Tone Wheel Tone Wheel 2WD The tone wheel for the front speed sensor is located in the rotor hub on 2-wheel drive models. On 4-wheel drive models, the tone wheel is located in the hub/bearing housing. The tone wheel is not a serviceable component. On 2-wheel drive models, the complete rotor and hub assembly will have to be replaced if the tone wheel is damaged. On 4-wheel drive models, the hub/bearing must be replaced, if the tone wheel is damaged. Rear Tone Wheel The toothed exciter ring is press-fitted onto the differential carrier next to the final drive ring gear in the differential case. If the ring is damaged, refer to Transmission and Drivetrain for service procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature Sensor, Cylinder Head Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 637 Engine Coolant Temperature Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 638 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 9 ECT Sensor To perform a complete test of the Engine Coolant Temperature (ECT) sensor and its circuitry, refer to Powertrain Management/Computers and Controls. To test the sensor only, refer to the following: 1. The ECT sensor is equipped with a 9 inch long jumper harness. This harness connects the ECT sensor to the main engine wiring harness. The end of the harness is located near the top of the fuel filter. It is used for sensor tests. Disconnect jumper harness connector from main engine wiring harness. ECT Sensor Resistance -- Ohms 2. Test resistance of sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the jumper harness terminals) should be as shown in ECT SENSOR RESISTANCE (OHMS) chart. Replace sensor if it is not within range of resistance specified in chart. 3. Test continuity of the wire harness between the PCM wire harness connector and the ECT sensor connector terminals. Refer to Group 8, Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 4. After tests are completed, connect jumper harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 639 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 13 ECT Sensor The Engine Coolant Temperature (ECT) sensor is located on the left side of the cylinder head behind the fuel filter and below the intake manifold. REMOVAL WARNING: THE COOLING SYSTEM MAY BE UNDER PRESSURE. HOT COOLANT CAN CAUSE BURNS. 1. Partially drain cooling system until coolant level is below cylinder head. 2. Drain and remove fuel filter/water separator. 3. Disconnect ECT sensor pigtail harness connector from sensor. 4. Remove ECT sensor from cylinder head. INSTALLATION 1. Apply sealant to sensor threads. 2. Install ECT sensor into cylinder head. Tighten to 55 Nm (40 ft. lbs.) torque. 3. Connect ECT sensor wire connector. 4. Install fuel filter and bleed fuel. 5. Fill cooling system and check for coolant leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation Cruise Control Switch: Description and Operation SYSTEM OPERATION Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver's airbag module. Within the two switch modules, five momentary contact switches, supporting seven different speed control functions are used. The outputs from these switches are filtered into one input. The powertrain Control Module (PCM) determines which output has been applied through resistive multiplexing. The input circuit voltage is measured by the PCM to determine which switch function has been selected. A speed control indicator lamp, located on the instrument panel cluster is energized by the PCM via the CCD Bus. This occurs when speed control system power has been turned ON, and the engine is running. The two switch modules are labeled: ON/OFF, SET, RESUME/ACCEL, CANCEL and COAST. Refer to the owner's manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one individual switch fails, the switch module must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 644 Cruise Control Switch: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/Testing and Inspection. See: Powertrain Management/Computers and Control Systems/Testing and Inspection For complete speed control system diagnosis, refer to the appropriate Powertrain Diagnostic Procedures. To test each of the speed control switches only, refer to the following: WARNING: BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS, YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect negative battery cable. Wait 2 minutes for airbag system capacitor to discharge. 2. Remove the two speed control switch modules from steering wheel. Refer to the replacement for procedures. Speed Control Switch Continuity (Typical Switch Shown) 3. Check continuity of each individual speed control switch module as shown in chart. If OK, reinstall switch. If not OK, replace switch module assembly. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Page 645 Cruise Control Switch: Service and Repair REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. THEN WAIT TWO MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE INJURY. 1. Disconnect and isolate negative battery cable. 2. Remove airbag module. Refer to Air Bags and Seat Belts/Air Bags for procedures. Speed Control Switches 3. Remove switch-to-steering wheel mounting screws. 4. Remove switch. 5. Remove electrical connector at switch. INSTALLATION 1. Install electrical connector to switch. 2. Install switch and mounting screws. 3. Tighten screws to 1.5 N.m (14 in. lbs.) torque. 4. Install airbag module. Refer to Air Bags and Seat Belts/Air Bags for procedures. 5. Connect negative battery cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Description and Operation Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation SYSTEM OPERATION The Vehicle Speed Sensor (VSS) is no longer used for any Dodge truck in the 1998 model year. Vehicle speed and distance covered are measured by the Rear Wheel Speed Sensor. The sensor is mounted to the rear axle. A signal is sent from this sensor to the Controller Antilock Brake (CAB) computer. A signal is then sent from the CAB to the Powertrain Control Module (PCM) to determine vehicle speed and distance covered. The PCM will then determine strategies for speed control system operation. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations The oil pressure sender unit is installed into the oil pressure galley on the engine block and behind the power steering pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions Oil Pressure Sender: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 655 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 656 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 657 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 658 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 659 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 660 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 661 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 662 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 663 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 664 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 665 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 666 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 667 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 668 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 669 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 670 Oil Pressure Sender: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 671 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 672 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 673 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Diagrams > Page 674 Oil Pressure Sender: Service and Repair 1. Disconnect negative battery cable. 2. Remove electrical connector from oil pressure sender unit. 3. Remove oil pressure sender unit from engine block. 4. Installation is reverse of removal noting the following: a. Check the seal/O-ring for serviceability. b. Torque the oil pressure sender unit to 16Nm (144 in. lb.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 679 vi Revision to the Trouble Code Test menu Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 680 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 681 589 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 682 589A Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 683 589B Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 684 589C Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 685 589D Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 686 589E Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 687 589F Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 688 Oil Pressure Sensor: Locations The oil pressure sender unit is installed into the oil pressure galley on the engine block and behind the power steering pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 689 Oil Pressure Sensor: Service and Repair 1. Disconnect negative battery cable. 2. Remove electrical connector from oil pressure sender unit. 3. Remove oil pressure sender unit from engine block. 4. Installation is reverse of removal noting the following: a. Check the seal/O-ring for serviceability. b. Torque the oil pressure sender unit to 16Nm (144 in. lb.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Ambient Temperature Sensor/Road Temperature Sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 694 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Ambient Temperature Sensor Remove/Install 2. Locate the ambient temperature sensor, on the underside of the hood near the hood latch striker. 3. Unplug the wire harness connector from the ambient temperature sensor. 4. Remove the screw that secures the ambient temperature sensor to the inner hood reinforcement. 5. Remove the ambient temperature sensor from under the hood. 6. Reverse the removal procedures to install. Tighten the ambient temperature sensor mounting screw to 5.6 N.m (50 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation Blower Motor Switch: Description and Operation Blower Motor Switch The heater-only or heater-A/C blower motor is controlled by a four position rotary-type blower motor switch, mounted in the heater-A/C control panel. The switch allows the selection of one of four blower motor speeds, but can only be turned off by selecting the Off position with the heater-A/C mode control switch knob. The blower motor switch directs the blower motor ground path through the mode control switch to the blower motor resistor, or directly to ground, as required to achieve the selected blower motor speed. The blower motor switch cannot be repaired and, if faulty or damaged, the entire heater-only or Heater-A/C control unit must be replaced. The blower motor switch knob is serviced separately Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Description and Operation > Page 698 Blower Motor Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check for battery voltage at the fuse in the Power Distribution Center (PDC). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the heater-A/C control from the instrument panel. Check for continuity between the ground circuit cavity of the heater-A/C control wire harness connector and a good ground. There should be continuity. If OK, go to Step 3. If not OK, repair the open circuit to ground as required. 3. With the heater-A/C control wire harness connector unplugged, place the heater-A/C mode control switch knob in any position except the Off position. Check for continuity between the ground circuit terminal and each of the blower motor driver circuit terminals of the heater-A/C control as you move the blower motor switch knob to each of the four speed positions. There should be continuity at each driver circuit terminal in only one blower motor switch speed position. If OK, test and repair the blower driver circuits between the heater-A/C control connector and the blower motor resistor as required. If not OK, replace the faulty heater-A/C control unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation High Pressure Sensor / Switch: Description and Operation High Pressure Cut-Off Switch The high pressure cut-off switch is located on the discharge line near the compressor. The switch is screwed onto a fitting that contains a Schrader-type valve, which allows the switch to be serviced without discharging the refrigerant system. The discharge line fitting is equipped with an O-ring to seal the switch connection. The high pressure cut-off switch is connected in series electrically with the low pressure cycling clutch switch between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This prevents compressor operation when the discharge line pressure approaches high levels. The high pressure cut-off switch contacts are open when the discharge line pressure rises above about 3100 to 3375 kPa (450 to 490 psi). The switch contacts will close when the discharge line pressure drops to about 1860 to 2275 kPa (270 to 330 psi). When checking refrigerant system pressures with a manifold gauge set, keep in mind that the indicated pressures will be about 172 kPa (25 psi) below the actual switch pressure values due to the pressure drop that occurs in the refrigerant system between the switch and the high pressure service port. The high pressure cut-off switch is a factory-calibrated unit. The switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 703 High Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the high pressure cut-off switch, verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures for more information. 1. Disconnect and isolate the battery negative cable. 2. Unplug the high pressure cut-off switch wire harness connector from the switch on the refrigerant system fitting. 3. Check for continuity between the two terminals of the high pressure cut-off switch. There should be continuity If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > High Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 704 High Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. High Pressure Cut-Off Switch Remove/Install 2. Unplug the wire harness connector from the high pressure cut-off switch, which is mounted to a fitting on the discharge line between the compressor and the condenser inlet. 3. Unscrew the high pressure cut-off switch from the discharge line fitting. 4. Remove the high pressure cut-off switch from the vehicle. 5. Remove the O-ring seal from the discharge line fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the discharge line fitting. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the vehicle. 2. Install and tighten the high pressure cut-off switch on the discharge line fitting. 3. Plug the wire harness connector into the high pressure cut-off switch. 4. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation Low Pressure Sensor / Switch: Description and Operation Low Pressure Cycling Clutch Switch The low pressure cycling clutch switch is located on the top of the accumulator. The switch is screwed onto an accumulator fitting that contains a Schrader type valve, which allows the switch to be serviced without discharging the refrigerant system. The accumulator fitting is equipped with an O-ring to seal the switch connection. The low pressure cycling clutch switch is connected in series electrically with the high pressure cut-off switch and the heater-A/C controls, between ground and the Powertrain Control Module (PCM). The switch contacts open and close causing the PCM to turn the compressor clutch on and off. This regulates the refrigerant system pressure and controls evaporator temperature. Controlling evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow. The low pressure cycling clutch switch contacts are open when the suction pressure is about 172 kPa (25 psi) or lower. The switch contacts will close when the suction pressure rises to about 296 kPa (43 psi) or above. Lower ambient temperatures, below about 1° C (30° F), will also cause the switch contacts to open. This is due to the pressure/temperature relationship of the refrigerant in the system. The low pressure cycling clutch switch is afactory calibratedd unit. It cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 708 Low Pressure Sensor / Switch: Testing and Inspection Before performing diagnosis of the low pressure cycling clutch switch, be certain that the switch is properly installed on the accumulator fitting. If the switch is too loose it may not open the Schrader-type valve in the accumulator fitting, which will prevent the switch from correctly monitoring the refrigerant system pressure. Also verify that the refrigerant system has the correct refrigerant charge. See Refrigerant System Charge in the Service Procedures for more information. Remember that lower ambient temperatures, below about -1° C (30° F), during cold weather will open the switch contacts and prevent compressor operation due to the pressure/temperature relationship of the refrigerant. 1. Disconnect and isolate the battery negative cable. 2. Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accumulator fitting. 3. Install a jumper wire between the two cavities of the low pressure cycling clutch switch wire harness connector. 4. Connect a manifold gauge set to the refrigerant system service ports. See Refrigerant System Service Equipment and Refrigerant System Service Ports in the Description and Operation for more information. 5. Connect the battery negative cable. 6. Place the heater-A/C mode control switch knob in any A/C position and start the engine. 7. Check for continuity between the two terminals of the low pressure cycling clutch switch. There should be continuity with a suction pressure reading of 296 kPa (43 psi) or above, and no continuity with a suction pressure reading of 172 kPa (25 psi) or below. If OK, test and repair the A/C switch sense circuit as required. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Low Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Page 709 Low Pressure Sensor / Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Low Pressure Cycling Clutch Switch Remove/Install 2. Unplug the wire harness connector from the low pressure cycling clutch switch on the top of the accumulator. 3. Unscrew the low pressure cycling clutch switch from the fitting on the top of the accumulator. 4. Remove the O-ring seal from the accumulator fitting and discard. INSTALLATION 1. Lubricate a new O-ring seal with clean refrigerant oil and install it on the accumulator fitting. Use only the specified 0-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Install and tighten the low pressure cycling clutch switch on the accumulator fitting. The switch should be hand-tightened onto the accumulator fitting. 3. Plug the wire harness connector into the low pressure cycling clutch switch. 4. Connect the battery negative cable. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Dimmer Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 715 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 716 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 718 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 719 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 720 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 721 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 722 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 723 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 724 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 725 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 726 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 727 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 728 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 729 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 730 Dimmer Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 731 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 732 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 737 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 738 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 739 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 740 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 741 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 742 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 743 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 744 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 745 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 746 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 747 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 748 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 749 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 750 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 751 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 752 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 754 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 755 Door Switch: Description and Operation SYSTEM OPERATION The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Seatbelt Control Timer Module (SCTM) when a door is opened, and open the ground path when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. Refer to Door Jamb Switch in the Replacement of Vehicle Theft Security Systems for the service procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 756 Door Switch: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module 1. Disconnect and isolate the battery negative cable. Unplug the inoperative (driver or passenger) door jamb switch from its wire harness connector. Check for continuity between the ground circuit cavity of the door jamb switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the circuit to ground as required. 2. Check for continuity between the door jamb switch ground circuit terminal and each of the other two terminals of the door jamb switch. There should be continuity with the switch plunger released, and no continuity with the switch plunger depressed. If OK, go to Step 3. If not OK, replace the faulty switch. 3. Unplug the Seatbelt Control Timer Module (SCTM) wire harness connector. Check for continuity between the inoperative (driver or passenger) door ajar switch sense circuit cavity of the SCTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the short circuit as required. 4. Check for continuity between the inoperative (driver or passenger) door ajar switch sense circuit cavities of the SCTM wire harness connector and the door jamb switch wire harness connector. There should be continuity. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Diagrams > Page 757 Door Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and- forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the door jamb switch out from the pillar far enough to access the wire harness connector. 4. Unplug the door jamb switch from the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest for Fuel Gauge Sender: > 08-42-99 > Dec > 99 > Fuel Gauge - Reads Full for an Excessive Time Fuel Gauge Sender: Customer Interest Fuel Gauge - Reads Full for an Excessive Time NUMBER: 08-42-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: The Fuel Gauge Reads Full For An Excessive Period Of Time OVERVIEW: This bulletin involves installing a new fuel pump module. MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE. SYMPTOM/CONDITION: After driving over 200 miles, the fuel gauge may read full until the vehicle travels over a bump in the road and then the gauge operates normally. DIAGNOSIS: This condition may be caused by the float in the fuel pump module sticking and may be difficult to diagnose. Perform the repair procedure if the customer's concern matches the description identified in the Symptom/Condition. PARTS REQUIRED: 1 04897668AE Module, Fuel Pump REPAIR PROCEDURE: 1. Using the procedure identified in the 1999 Ram Truck Service Manual (Publication No. 81-370-9108), page 14-92, replace the fuel pump module with p/n 04897668AE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-50-05-90 1.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 08-42-99 > Dec > 99 > Fuel Gauge - Reads Full for an Excessive Time Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Reads Full for an Excessive Time NUMBER: 08-42-99 GROUP: Electrical DATE: Dec. 17, 1999 SUBJECT: The Fuel Gauge Reads Full For An Excessive Period Of Time OVERVIEW: This bulletin involves installing a new fuel pump module. MODELS: 1998 - 1999 (BR/BE) Ram Truck NOTE: THIS BULLETIN APPLIES TO VEHICLE EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE. SYMPTOM/CONDITION: After driving over 200 miles, the fuel gauge may read full until the vehicle travels over a bump in the road and then the gauge operates normally. DIAGNOSIS: This condition may be caused by the float in the fuel pump module sticking and may be difficult to diagnose. Perform the repair procedure if the customer's concern matches the description identified in the Symptom/Condition. PARTS REQUIRED: 1 04897668AE Module, Fuel Pump REPAIR PROCEDURE: 1. Using the procedure identified in the 1999 Ram Truck Service Manual (Publication No. 81-370-9108), page 14-92, replace the fuel pump module with p/n 04897668AE. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 14-50-05-90 1.3 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 773 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 774 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 775 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 776 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 777 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 778 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 779 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 780 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 781 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 782 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 783 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 784 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 785 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 786 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 787 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 788 Fuel Gauge Sender: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 789 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 790 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 791 Fuel Gauge Sender: Electrical Diagrams Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Diagrams > Diagram Information and Instructions > Page 792 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations Fuel Temperature Sensor, Water-In-Fuel Sensor, Fuel Transfer (Lift) Pump, Pre-Filter, Fuel Heater Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Water In Fuel Sensor > Component Information > Locations > Page 796 Water-In-Fuel Sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications Backup Lamp Switch: Specifications Mounting .............................................................................................................................................. .............................. 22 - 34 Nm (193 - 300 inch lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Specifications > Page 801 Transmission Connectors Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions Backup Lamp Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 804 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 805 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 806 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 807 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 808 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 809 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 810 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 811 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 812 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 813 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 814 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 815 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 816 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 817 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 818 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 819 Backup Lamp Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 820 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 821 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 822 Rear Lighting Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams > Page 823 Backup Lamp Switch: Service and Repair Backup Light Switch Location The backup light switch is located at the left (driver) side of the cover. The switch plunger is operated by the fifth-reverse shift rail. The switch can be replaced with the transmission in, or out of the vehicle. A gasket must used with the switch. Apply sealer to the switch threads before installation. Tightening torque for the switch is 22 - 34 Nm (192 - 300 inch lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Lamp Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 827 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information Brake Light Switch: Description and Operation General Information Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is mounted on the brake pedal mounting bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > General Information > Page 830 Brake Light Switch: Description and Operation Switch With RWAL System The primary function of the switch,is to turn on the stop lamps during braking. The switch is also used to send signals to components that must know when the brakes are applied, such as the Powertrain Control Module (PCM), which uses the signal to cancel speed control. The Controller Antilock Brake (CAB) uses the brake switch signal to monitor brake pedal application. When the switch contacts open (brakes applied), the CAB receives the brake applied signal. The CAB then monitors the ABS system to anticipate the need for an ABS stop. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 831 Brake Light Switch: Testing and Inspection GENERAL INFORMATION Stop lamp switch operation can be tested with an ohmmeter. The ohmmeter is used to check continuity between the pin terminals at different plunger positions. NOTE: The switch wire harness must be disconnected before testing switch continuity. SWITCH CIRCUIT IDENTIFICATION Stop Lamp Switch Terminal Identification - Terminals 1 and 2 are for the RWAL/ABS module and Powertrain Control Module (PCM) circuit. - Terminals 5 and 6 are for the stop lamp circuit. - Terminals 3 and 4 are for the speed control circuit. SWITCH CONTINUITY TEST 1. Check continuity between terminal pins 5 and 6 as follows: a. Pull plunger all the way out to fully extended position. b. Attach test leads to pins 5 and 6 and note ohmmeter reading. c. If continuity exists, proceed to next test. Replace switch if meter indicates lack of continuity (shorted or open). 2. Check continuity between terminal pins 1 and 2 and pins 3 and 4 as follows: a. Push switch plunger inward to fully retracted position. b. Attach test leads to pins 1 and 2 and note ohmmeter reading. c. If continuity exists, switch is OK. Replace switch if meter indicates lack of continuity (switch is open). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 832 Brake Light Switch: Adjustments 1. Push and hold brake pedal down 2. Pull switch plunger all the way out to fully extended position. 3. Push switch plunger inward 4 detent positions (or clicks). This is required preset position. Plunger will extend approximately 14 mm (0.55 inch) out of housing at this setting. 4. Release brake pedal. Then lightly pull pedal fully rearward. Pedal will adjust switch plunger to correct position as pedal is moved to rear. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 833 Brake Light Switch: Service and Repair REMOVAL 1. Remove knee bolster for access to stop lamp switch and pedal. Stop Lamp Switch And Harness Connector 2. Disconnect switch harness. 3. Press and hold brake pedal in applied position. 4. Rotate switch counterclockwise about 30° to align switch lock tab with notch in bracket. 5. Pull switch rearward out of mounting bracket and release brake pedal. INSTALLATION 1. Pull switch plunger all the way out to fully extended position. 2. Push switch plunger inward 4 detent positions (or clicks). This is required preset position for switch installation. Plunger will extend approximately 14 mm (0.55 inch) out of housing at this setting. 3. Connect harness wires to switch. 4. Press and hold brake pedal down. Stop Lamp Switch 5. Install switch. Align tab on switch with notch in switch bracket. Then insert switch in bracket and turn it clockwise about 30° to lock it in place. 6. Release brake pedal. Then lightly pull pedal fully rearward. Pedal will adjust switch plunger to correct position as pedal is moved to rear. CAUTION: Do not use excessive force to move the pedal rearward for switch adjustment. Excessive force will damage the switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions Door Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 838 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 839 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 840 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 841 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 842 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 843 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 844 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 845 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 846 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 847 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 848 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 849 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 850 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 851 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 852 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 853 Door Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 854 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 855 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 856 Door Switch: Description and Operation SYSTEM OPERATION The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Seatbelt Control Timer Module (SCTM) when a door is opened, and open the ground path when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. Refer to Door Jamb Switch in the Replacement of Vehicle Theft Security Systems for the service procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 857 Door Switch: Testing and Inspection For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module 1. Disconnect and isolate the battery negative cable. Unplug the inoperative (driver or passenger) door jamb switch from its wire harness connector. Check for continuity between the ground circuit cavity of the door jamb switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the circuit to ground as required. 2. Check for continuity between the door jamb switch ground circuit terminal and each of the other two terminals of the door jamb switch. There should be continuity with the switch plunger released, and no continuity with the switch plunger depressed. If OK, go to Step 3. If not OK, replace the faulty switch. 3. Unplug the Seatbelt Control Timer Module (SCTM) wire harness connector. Check for continuity between the inoperative (driver or passenger) door ajar switch sense circuit cavity of the SCTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the short circuit as required. 4. Check for continuity between the inoperative (driver or passenger) door ajar switch sense circuit cavities of the SCTM wire harness connector and the door jamb switch wire harness connector. There should be continuity. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Diagrams > Page 858 Door Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and- forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the door jamb switch out from the pillar far enough to access the wire harness connector. 4. Unplug the door jamb switch from the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. See Cluster Bezel in the Replacement for the procedures. Foglamp Switch Remove/Install 3. Remove the three screws that secure the switch mounting plate to the instrument panel. 4. Pull the switch mounting plate away from the instrument panel far enough to access and unplug the wire harness connector from the back of the fog lamp switch. 5. Squeeze the tabs on the back of the fog lamp switch that secure it in the receptacle on the back of the switch mounting plate. 6. Pull the fog lamp switch out of the receptacle on the back of the switch mounting plate. 7. Reverse the removal procedures to install. Be certain that the fog lamp switch latches are fully engaged in the switch mounting plate receptacle. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch > Component Information > Service and Repair Glove Box Lamp Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the glove box from the instrument panel. See Glove Box in the Replacement for the procedures. Glove Box Lamp And Switch Remove/Install 3. Reach through and above the instrument panel glove box opening to unplug the two wire harness connectors from the glove box lamp and switch. 4. Reach through and above the instrument panel glove box opening to depress the retaining tabs on the top and bottom of the glove box lamp and switch housing. 5. While holding the retaining tabs depressed, push the glove box lamp and switch unit out through the hole in the mounting bracket on the instrument panel glove box opening upper reinforcement. 6. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation Hazard Warning Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A switch stalk that extends from the left side of the steering column is moved up or down to activate the right or left turn signals, respectively. A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the turn signal and hazard warning systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 868 Hazard Warning Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the multi-function switch wire harness connector. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Description and Operation > Page 869 Hazard Warning Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch mounting screws - 2 N.m (17 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Customer Interest for Headlamp Switch: > 08-13-98 > Mar > 98 > Headlamp Switch Knob - Pulls Out of Headlamp Switch Headlamp Switch: Customer Interest Headlamp Switch Knob - Pulls Out of Headlamp Switch NO: 08-13-98 GROUP: Electrical DATE: Mar. 27, 1998 SUBJECT: Headlamp Switch Knob Pulls Out Of Headlamp Switch MODELS: 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE BUILT BEFORE NOVEMBER 16, 1997 (MDH 1116XX). SYMPTOM/CONDITION: The headlamp switch knob may pull out of the headlamp switch when the switch is rotated to the full dim position and a side load is generated when headlamps are pulled ON. With this case, the head lamps activate when the knob is pulled out. The knob can be reinstalled back into the headlamp switch to turn the headlamps OFF. DIAGNOSIS: Rotate the headlamp switch knob to the full dim position. Then, apply pressure to the side of the knob and pull the knob to turn the headlamps ON. If the knob pulls out of the headlamp switch when the headlamps are turned ON, replace the knob using the following Repair Procedure. NOTE: IT MAY REQUIRE SEVERAL ATTEMPTS TO GET THE HEADLAMP SWITCH KNOB TO BE PULLED OUT OF THE SWITCH. PARTS REQUIRED: 1 56020060AB Knob, Headlamp Switch REPAIR PROCEDURE: This bulletin involves installing a revised headlamp switch knob. 1. With the headlamp switch knob removed (removed during the diagnosis), install revised headlamp switch knob, p/n 5602006OAB, into headlamp switch until the locking tab in the headlamp switch locks the knob into place. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-70-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Headlamp Switch: > 08-13-98 > Mar > 98 > Headlamp Switch Knob - Pulls Out of Headlamp Switch Headlamp Switch: All Technical Service Bulletins Headlamp Switch Knob - Pulls Out of Headlamp Switch NO: 08-13-98 GROUP: Electrical DATE: Mar. 27, 1998 SUBJECT: Headlamp Switch Knob Pulls Out Of Headlamp Switch MODELS: 1998 (AN) Dakota 1998 (BR/BE) Ram Truck 1998 (DN) Durango NOTE: THIS BULLETIN APPLIES TO VEHICLE BUILT BEFORE NOVEMBER 16, 1997 (MDH 1116XX). SYMPTOM/CONDITION: The headlamp switch knob may pull out of the headlamp switch when the switch is rotated to the full dim position and a side load is generated when headlamps are pulled ON. With this case, the head lamps activate when the knob is pulled out. The knob can be reinstalled back into the headlamp switch to turn the headlamps OFF. DIAGNOSIS: Rotate the headlamp switch knob to the full dim position. Then, apply pressure to the side of the knob and pull the knob to turn the headlamps ON. If the knob pulls out of the headlamp switch when the headlamps are turned ON, replace the knob using the following Repair Procedure. NOTE: IT MAY REQUIRE SEVERAL ATTEMPTS TO GET THE HEADLAMP SWITCH KNOB TO BE PULLED OUT OF THE SWITCH. PARTS REQUIRED: 1 56020060AB Knob, Headlamp Switch REPAIR PROCEDURE: This bulletin involves installing a revised headlamp switch knob. 1. With the headlamp switch knob removed (removed during the diagnosis), install revised headlamp switch knob, p/n 5602006OAB, into headlamp switch until the locking tab in the headlamp switch locks the knob into place. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation No: 23-42-70-90 0.2 Hrs. FAILURE CODE: P8 - New Part Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Technical Service Bulletins > Page 883 Headlamp Switch: Service and Repair REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - IF THE HEADLAMP SWITCH WAS ON, WAIT FIVE MINUTES TO ALLOW THE CERAMIC DIMMER RESISTOR TO COOL. IF THE CERAMIC DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT CAN BURN YOUR FINGERS. 1. Disconnect and isolate the battery negative cable. 2. Remove the cluster bezel from the instrument panel. See Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Cluster Bezel Replacement for the procedures. Headlamp Switch And Bezel Remove/Install 3. Remove the three screws that secure the headlamp switch bezel to the instrument panel. 4. Pull the headlamp switch and bezel out from the instrument panel far enough to access the wire harness connectors. 5. Unplug the two wire harness connectors from the headlamp switch. 6. Pull the headlamp switch control knob out to the On position stop. 7. Depress the headlamp switch knob and shaft release button on the top of the switch. 8. while holding the release button depressed, pull the knob and shaft out of the headlamp switch. 9. Remove the two push nut retainers that secure the headlamp switch bezel to the switch mounting bracket. 10. Remove the headlamp switch bezel from the switch mounting bracket. 11. Remove the spanner nut that secures the headlamp switch mounting bracket to the switch. 12. Remove the headlamp switch mounting bracket from the switch. 13. Reverse the removal procedures to install. Tighten the headlamp switch and bezel mounting screws to 2.2 N.m (20 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions Horn Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 888 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 889 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 890 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 891 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 892 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 893 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 894 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 895 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 896 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 897 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 898 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 899 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 900 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 901 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 902 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 903 Horn Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 904 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 905 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 906 Horn Switch: Description and Operation SYSTEM OPERATION A center-blow, resistive membrane-type horn switch is installed on the back side of the driver side airbag module trim cover in the center of the steering wheel. When the center area of the airbag trim cover is depressed, the horn switch completes a circuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switch to function. The horn switch is only serviced as a part of the airbag module trim cover. If the horn switch should fail, or if the airbag is deployed, the airbag module trim cover and horn switch must be replaced as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Diagrams > Page 907 Horn Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module 1. Disconnect and isolate the battery negative cable. Remove the steering column opening cover and knee blocker from the instrument panel. 2. Check for continuity between the metal steering column jacket and a good ground. There should be continuity. 3. Remove the driver side airbag module from the steering wheel. Refer to Air Bags and Seat Belts/Air Bags/Airbag Module Replacement for the procedures. Unplug the horn switch wire harness connectors from the airbag module. 4. Unplug the horn relay from the Power Distribution Center (PDC). Check for continuity between the steering column half of the horn switch feed wire harness connector and a good ground. There should be no continuity If OK, go to Step 5. If not OK, repair the short circuit as required. 5. Check for continuity between the steering column half of the horn switch feed wire harness connector and the horn relay control circuit cavity for the horn relay in the PDC. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should be no continuity. If OK, go to Step 7. If not OK, replace the faulty horn switch. 7. Depress the center of the airbag module trim cover and check for continuity between the horn switch feed wire and the horn switch ground wire on the airbag module. There should now be continuity. If not OK, replace the faulty horn switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch Horn Switch: Service and Repair Driver Side Airbag Trim Cover and Horn Switch REMOVAL WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. - THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the driver side airbag module from the steering wheel. See Air Bags and Seat Belts/Air Bags/Airbag Module Replacement for the procedures. 3. Disengage the horn switch feed wire retainer from the hole in the trim cover retainer on the back of the airbag housing. 4. Remove the three nuts that secure the trim cover retainer to the studs on the airbag housing. 5. Remove the horn switch ground wire eyelet from the lower left airbag housing stud. 6. Remove the trim cover retainer from the airbag housing studs. 7. Disengage the six trim cover locking blocks from the lip around the outside edge of the airbag housing and remove the housing from the cover. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE DRIVER SIDE AIRBAG MODULE, OR BECOMING ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG MODULE TRIM COVER AND THE DRIVER SIDE AIR- BAG MODULE. FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT. Driver Side Airbag Trim Cover Locking Blocks Engaged 8. When reinstalling the trim cover and horn switch, be certain that the locking blocks are fully engaged on the lip of the airbag housing. 9. When reinstalling the trim cover retainer, be certain that the tabs on the retainer are engaged in each of the retainer slots of the trim cover. 10. Install the horn switch ground wire eyelet over the lower left airbag housing stud. 11. Install and tighten the trim cover retainer nuts to 10 N.m (90 in. lbs.). 12. Reverse the remaining removal procedures to complete the installation, but do not connect the battery negative cable at this time. See Air Bags and Seat Belts/Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair > Driver Side Airbag Trim Cover and Horn Switch > Page 910 Horn Switch: Service and Repair Horn Switch REMOVAL AND INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH A DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTEGRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER-TRAINED AND AUTHORIZED DEALER SERVICE TECHNICIANS. FAILURE TO TAKE THE PROPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REFER TO DRIVER SIDE AIRBAG TRIM COVER AND HORN SWITCH IN THE REPLACEMENT OF PASSIVE RESTRAINT SYSTEMS FOR THE SERVICE PROCEDURES . Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions Interior Light Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 915 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 916 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 917 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 918 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 919 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 920 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 921 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 922 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 923 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 924 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 925 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 926 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 927 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 928 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 929 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 930 Interior Light Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 931 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 932 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Page 933 Interior Light Switch: Description and Operation SYSTEM OPERATION The door jamb switches are mounted to the door hinge pillars. The switches close a path to ground for the Seatbelt Control Timer Module (SCTM) when a door is opened, and open the ground path when a door is closed. The door jamb switches cannot be repaired and, if faulty or damaged, they must be replaced. Refer to Door Jamb Switch in the Replacement of Vehicle Theft Security Systems for the service procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Page 934 Interior Light Switch: Testing and Inspection 1. Disconnect and isolate the battery negative cable. Unplug the inoperative (driver or passenger) door jamb switch from its wire harness connector. Check for continuity between the ground circuit cavity of the door jamb switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the circuit to ground as required. 2. Check for continuity between the door jamb switch ground circuit terminal and each of the other two terminals of the door jamb switch. There should be continuity with the switch plunger released, and no continuity with the switch plunger depressed. If OK, go to Step 3. If not OK, replace the faulty switch. 3. Unplug the Seatbelt Control Timer Module (SCTM) wire harness connector. Check for continuity between the inoperative (driver or passenger) door ajar switch sense circuit cavity of the SCTM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 4. If not OK, repair the short circuit as required. 4. Check for continuity between the inoperative (driver or passenger) door ajar switch sense circuit cavities of the SCTM wire harness connector and the door jamb switch wire harness connector. There should be continuity. If not OK, repair the open circuit as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Diagrams > Page 935 Interior Light Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Grasp the body of the door jamb switch with a pair of pliers and move the switch gently back-and- forth while pulling it out of the door hinge pillar mounting hole. Door Jamb Switch Remove/Install 3. Pull the door jamb switch out from the pillar far enough to access the wire harness connector. 4. Unplug the door jamb switch from the wire harness connector. 5. Reverse the removal procedures to install. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation Turn Signal Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The turn signal and hazard warning switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A switch stalk that extends from the left side of the steering column is moved up or down to activate the right or left turn signals, respectively. A latching push-button that extends upward from the multi-function switch and through the top of the upper steering column shroud is used to control the hazard warning system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the turn signal and hazard warning systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 939 Turn Signal Switch: Testing and Inspection Perform the diagnosis of the hazard warning and/or turn signal systems as described before testing the multi-function switch. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. Unplug the multi-function switch wire harness connector. Multi-Function Switch Continuity 2. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 3. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the lighting circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Description and Operation > Page 940 Turn Signal Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multi-Function Switch Connector 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multifunction switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch mounting screws - 2 N.m (17 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations Battery Temp Sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 946 Battery Temperature Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 947 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Locations > Page 948 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor Location 1. The sensor is located under the battery and is attached (snapped into) the battery tray. On models equipped with a diesel engine (dual batteries), only one sensor is used. Location is under battery on drivers side of vehicle. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Replacement for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 951 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray On models equipped with a diesel engine (dual batteries), only one sensor is used. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Engine Coolant Temperature Sensor, Cylinder Head Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 955 Engine Coolant Temperature Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 956 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection Fig 9 ECT Sensor To perform a complete test of the Engine Coolant Temperature (ECT) sensor and its circuitry, refer to Powertrain Management/Computers and Controls. To test the sensor only, refer to the following: 1. The ECT sensor is equipped with a 9 inch long jumper harness. This harness connects the ECT sensor to the main engine wiring harness. The end of the harness is located near the top of the fuel filter. It is used for sensor tests. Disconnect jumper harness connector from main engine wiring harness. ECT Sensor Resistance -- Ohms 2. Test resistance of sensor with a high input impedance (digital) volt-ohmmeter. The resistance (as measured across the jumper harness terminals) should be as shown in ECT SENSOR RESISTANCE (OHMS) chart. Replace sensor if it is not within range of resistance specified in chart. 3. Test continuity of the wire harness between the PCM wire harness connector and the ECT sensor connector terminals. Refer to Group 8, Wiring for terminal/cavity locations. Repair the wire harness if an open circuit is indicated. 4. After tests are completed, connect jumper harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 957 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Fig 13 ECT Sensor The Engine Coolant Temperature (ECT) sensor is located on the left side of the cylinder head behind the fuel filter and below the intake manifold. REMOVAL WARNING: THE COOLING SYSTEM MAY BE UNDER PRESSURE. HOT COOLANT CAN CAUSE BURNS. 1. Partially drain cooling system until coolant level is below cylinder head. 2. Drain and remove fuel filter/water separator. 3. Disconnect ECT sensor pigtail harness connector from sensor. 4. Remove ECT sensor from cylinder head. INSTALLATION 1. Apply sealant to sensor threads. 2. Install ECT sensor into cylinder head. Tighten to 55 Nm (40 ft. lbs.) torque. 3. Connect ECT sensor wire connector. 4. Install fuel filter and bleed fuel. 5. Fill cooling system and check for coolant leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations Engine Speed Sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 961 Crankshaft Position Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 962 Engine Speed Sensor: Description and Operation PURPOSE It generates an RPM signal to the Powertrain Control Module (PCM). OPERATION The engine speed sensor input is used along with the vehicle speed sensor and throttle position sensor (TPS) inputs to determine when to shift the automatic transmission into and out of overdrive. The speed sensor signal is also used as an input for the Automatic Shutdown relay (ASD) (for control of generator field), vehicle speed control, torque convertor electrical engagement and instrument panel mounted tachometer. CIRCUIT OPERATION Circuit K6 supplies 5 Volts from the Powertrain Control Module (PCM) to the engine speed sensor. The K6 circuit connects to cavity A17 of the PCM connector. Circuit K24 from the engine speed sensor provides an input signal to the PCM. The K24 circuit connects to cavity A8 of the PCM connector. The PCM provides a ground for the engine speed sensor signal (circuit K24) through circuit K4. Circuit K4 connects to cavity A4 of the PCM connector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Speed Sensor > Component Information > Locations > Page 963 Engine Speed Sensor: Service and Repair The engine speed (rpm) sensor is located on the front of engine. Spacers located behind the sensor are used to position sensor over the vibration damper. Before removing sensor and its pigtail wiring harness, note position and routing of harness. This routing must be maintained to prevent wiring from contacting belt or pulleys. REMOVAL 1. Disconnect speed sensor pigtail harness from main engine wiring harness near front/top of engine. 2. Remove clip bolts from sensor pigtail wiring harness. 3. Remove two speed sensor mounting nuts. 4. Remove speed sensor and its mounting spacers from engine. NOTES: - The engine speed sensor has 2 slotted holes to adjust its depth. A brass (non-magnetic) feeler gauge must be used to adjust sensor. - Sensor-to-vibration damper air gap: 1.25 MM (0.049 in.) minimum to 1.30 MM (0.051 in.) maximum. INSTALLATION/ADJUSTMENT 1. Position speed sensor, its mounting spacers and two mounting nuts to engine. Install mounting nuts finger tight. 2. Route sensor wiring harness behind engine pulleys. Install and tighten wiring harness clip bolts. 3. Place feeler gauge between bottom of sensor and top of vibration dampener. 4. Gently seat (push down) sensor until it contacts feeler gauge. Sensor should be flat to feeler gauge. Slide sensor through slotted holes until flat to feeler gauge. Be sure sensor is not near either of notches on vibration damper. If sensor is adjusted at or near these notches, it will be damaged when engine is started. 5. Tighten sensor mounting nuts to 24 N.m (18 ft. lbs.) torque. 6. Remove feeler gauge. 7. Connect sensor electrical pigtail connector to main engine wiring harness. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Intake Air Temperature Sensor: Locations Fig. 24 Air Temperature Sensor Location The Intake Air Temperature Sensor is located on the top of the intake manifold and to the rear of the intake manifold air heater. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 967 Intake Air Temperature Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions Oil Pressure Sensor: Technical Service Bulletins Engine Controls/Fuel System - Manual Revisions NUMBER: 26-01-99C GROUP: Miscellaneous DATE: January, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Powertrain 2.5L. 3.9L, 5.2L, 5.9L, 8.0 SFI, Mechanical Injected Diesel Diagnostic Manual - Publication Number 81-699-97027 DESCRIPTION OF CHANGES Revision to the Table of Contents Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 972 vi Revision to the Trouble Code Test menu Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 973 538 Revision to the Oil Pressure Sensor test 589, 589A through 589F Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 974 589 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 975 589A Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 976 589B Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 977 589C Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 978 589D Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 979 589E Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Engine Controls/Fuel System - Manual Revisions > Page 980 589F Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 981 Oil Pressure Sensor: Locations The oil pressure sender unit is installed into the oil pressure galley on the engine block and behind the power steering pump. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Technical Service Bulletins > Page 982 Oil Pressure Sensor: Service and Repair 1. Disconnect negative battery cable. 2. Remove electrical connector from oil pressure sender unit. 3. Remove oil pressure sender unit from engine block. 4. Installation is reverse of removal noting the following: a. Check the seal/O-ring for serviceability. b. Torque the oil pressure sender unit to 16Nm (144 in. lb.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine/Engine Controls - Manual Revisions Oxygen Sensor: Technical Service Bulletins Engine/Engine Controls - Manual Revisions NUMBER: 26-06-98J GROUP: Miscellaneous DATE: June, 1998 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Ram Truck Service Manual - Publication Number 81-370-8108 DESCRIPTION OF CHANGES Revisions to the heated oxygen sensor wiring Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine/Engine Controls - Manual Revisions > Page 987 8W-30-17 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine/Engine Controls - Manual Revisions > Page 988 8W-80-66 Revision to the oil pan drain plug torque Spec. (60 Nm - 44 ft. Lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine/Engine Controls - Manual Revisions > Page 989 9-213 Revision to the turbo charger waste gate adjustment specifications Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine/Engine Controls - Manual Revisions > Page 990 11-20 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 995 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 996 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 997 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 998 152 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 999 156 Revision to the Fuel System Rich test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1000 316 Revisions to the Throttle Position sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1001 620 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1002 622 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1003 Throttle Position Sensor: Locations Throttle Position Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1004 Throttle Position Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1005 Throttle Position Sensor: Description and Operation The TPS provides throttle position input signals to the Powertrain Control Module (PCM). This input signal is used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1006 Throttle Position Sensor: Testing and Inspection The throttle position sensor (TPS) is used on diesel powered engines only when equipped with an automatic transmission and/or an Exhaust Gas Recirculation (EGR) system. If the TPS is to be replaced on a diesel engine, it must be tested/adjusted after replacement. REMOVAL 1. Disconnect electrical connector on bottom of TPS. 2. Remove two TPS mounting bolts. 3. Remove sensor from bracket. INSTALLATION 1. Position TPS to mounting bracket. The electrical connector should be facing downward. NOTE: The TPS is spring loaded. After positioning the TPS to its mounting bracket, rotate TPS on bracket in a counterclockwise direction until two bolt holes align. 2. Install and tighten two bolts. 3. Connect electrical connector on bottom of TPS. 4. Operate the throttle by hand to check for binding. 5. The TPS voltage must now be tested and (if necessary) adjusted. Refer to the following: THROTTLE POSITION SENSOR TESTING & ADJUSTMENT CAUTION: Before attempting to test TPS, verify linkage adjustment dimension. This dimension MUST be 126.5 mm (5.0 inches) BEFORE testing. For linkage adjustment procedures, refer to Throttle Linkage Adjustment-Diesel Engine. CAUTION: Before testing TPS, verify that engine is set at correct low idle speed. Refer to Idle Speed Adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1007 1. After confirming correct linkage adjustment and idle speed, proceed to the following: 2. Attach a paper clip into center terminal of TPS electrical connector. Do not remove connector from TPS for this test. 3. Attach positive lead of a voltmeter to this paper clip and negative lead to a good ground. 4. Turn ignition switch to ON position. Do not start engine. 5. The voltage at TPS center terminal should be 1.0 volt (+/- 0.2 volt) with linkage at idle position. At wide open throttle (WOT), output voltage must be 2.2-to-2.9 volts higher than at idle speed. If voltage is not correct, proceed to adjusting linkage. 6. The throttle lever rod connecting throttle lever to fuel injection pump lever is adjustable. To prevent damage to ends of linkage, attach locking-type pliers to flat located on throttle lever rod before loosening locknuts. 7. Loosen lever nut. This nut is close to the flat. 8. Unsnap lever socket from lever. 9. Slowly rotate the flat on linkage rod (lengthen or shorten) to achieve 1.0 volt (+/- 0.2 volts) on voltmeter with linkage in idle position. At wide open throttle (WOT), output voltage must be 2.2-to- 2.9 volts higher than at idle speed. DO NOT lengthen or shorten linkage rod more than 1 mm from dimension shown. If voltage requirements cannot be met by linkage adjustment (125.6 to 127.6 mm), replace TPS. 10. Tighten rod nut after adjustment. 11. With engine OFF, operate throttle from accelerator pedal and check for throttle lever action and binding. Be sure throttle lever stop is against low idle speed screw after throttle is released. 12. Be sure of wide open throttle (WOT) when accelerator pedal is pressed to the floor. This is checked by observing throttle lever breakover position. Proceed to the following: a. Key OFF and engine OFF for this test. b. Two people are needed for this test. From inside of vehicle, press accelerator pedal about half-way to floor. Movement of both throttle lever and throttle lever-to-injection pump lever linkage rod should be observed. c. Continue to press accelerator pedal to floor. If throttle lever breakover is operating correctly, the throttle lever-to-injection pump lever linkage rod should have stopped moving while throttle lever continues to move towards rear of vehicle. 13. Again, check and verify low idle speed. Adjust if necessary Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1008 Throttle Position Sensor: Service and Repair The throttle position sensor (TPS) is used on diesel powered engines only when equipped with an automatic transmission and/or an Exhaust Gas Recirculation (EGR) system. If the TPS is to be replaced on a diesel engine, it must be tested/adjusted after replacement. REMOVAL 1. Disconnect electrical connector on bottom of TPS. 2. Remove two TPS mounting bolts. 3. Remove sensor from bracket. INSTALLATION 1. Position TPS to mounting bracket. The electrical connector should be facing downward. NOTE: The TPS is spring loaded. After positioning the TPS to its mounting bracket, rotate TPS on bracket in a counterclockwise direction until two bolt holes align. 2. Install and tighten two bolts. 3. Connect electrical connector on bottom of TPS. 4. Operate the throttle by hand to check for binding. 5. The TPS voltage must now be tested and (if necessary) adjusted. Refer to the following: THROTTLE POSITION SENSOR TESTING & ADJUSTMENT CAUTION: Before attempting to test TPS, verify linkage adjustment dimension. This dimension MUST be 126.5 mm (5.0 inches) BEFORE testing. For linkage adjustment procedures, refer to Throttle Linkage Adjustment-Diesel Engine. CAUTION: Before testing TPS, verify that engine is set at correct low idle speed. Refer to Idle Speed Adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1009 1. After confirming correct linkage adjustment and idle speed, proceed to the following: 2. Attach a paper clip into center terminal of TPS electrical connector. Do not remove connector from TPS for this test. 3. Attach positive lead of a voltmeter to this paper clip and negative lead to a good ground. 4. Turn ignition switch to ON position. Do not start engine. 5. The voltage at TPS center terminal should be 1.0 volt (+/- 0.2 volt) with linkage at idle position. At wide open throttle (WOT), output voltage must be 2.2-to-2.9 volts higher than at idle speed. If voltage is not correct, proceed to adjusting linkage. 6. The throttle lever rod connecting throttle lever to fuel injection pump lever is adjustable. To prevent damage to ends of linkage, attach locking-type pliers to flat located on throttle lever rod before loosening locknuts. 7. Loosen lever nut. This nut is close to the flat. 8. Unsnap lever socket from lever. 9. Slowly rotate the flat on linkage rod (lengthen or shorten) to achieve 1.0 volt (+/- 0.2 volts) on voltmeter with linkage in idle position. At wide open throttle (WOT), output voltage must be 2.2-to- 2.9 volts higher than at idle speed. DO NOT lengthen or shorten linkage rod more than 1 mm from dimension shown. If voltage requirements cannot be met by linkage adjustment (125.6 to 127.6 mm), replace TPS. 10. Tighten rod nut after adjustment. 11. With engine OFF, operate throttle from accelerator pedal and check for throttle lever action and binding. Be sure throttle lever stop is against low idle speed screw after throttle is released. 12. Be sure of wide open throttle (WOT) when accelerator pedal is pressed to the floor. This is checked by observing throttle lever breakover position. Proceed to the following: a. Key OFF and engine OFF for this test. b. Two people are needed for this test. From inside of vehicle, press accelerator pedal about half-way to floor. Movement of both throttle lever and throttle lever-to-injection pump lever linkage rod should be observed. c. Continue to press accelerator pedal to floor. If throttle lever breakover is operating correctly, the throttle lever-to-injection pump lever linkage rod should have stopped moving while throttle lever continues to move towards rear of vehicle. 13. Again, check and verify low idle speed. Adjust if necessary Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1013 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Recalls for Vehicle Speed Sensor: > NHTSA98V209000 > Sep > 98 > Recall 98V209000: Vehicle Speed Sensor/Controller Defect Vehicle Speed Sensor: Recalls Recall 98V209000: Vehicle Speed Sensor/Controller Defect Light duty pickup trucks equipped with 5.9L - 24 valve diesel engine. An intermittent high engine idle condition can occur due to a malfunction of the vehicle speed sensor. This creates a signal which is misinterpreted by the engine control software, causing a high idle speed condition. Dealers will replace the engine controller software to correct erroneous speed sensor signals. Owner notification began September 28, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor: > NHTSA98V209000 > Sep > 98 > Recall 98V209000: Vehicle Speed Sensor/Controller Defect Vehicle Speed Sensor: All Technical Service Bulletins Recall 98V209000: Vehicle Speed Sensor/Controller Defect Light duty pickup trucks equipped with 5.9L - 24 valve diesel engine. An intermittent high engine idle condition can occur due to a malfunction of the vehicle speed sensor. This creates a signal which is misinterpreted by the engine control software, causing a high idle speed condition. Dealers will replace the engine controller software to correct erroneous speed sensor signals. Owner notification began September 28, 1998. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact Chrysler at 1-800-992-1997. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > RWAL Vehicle Speed Sensor: Locations RWAL Rear Speed Sensor Mounting Rear wheel speed sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > RWAL > Page 1029 Vehicle Speed Sensor: Locations 4WAL Rear Speed Sensor Mounting Rear wheel speed sensor Front Speed Sensor Mounting Front wheel speed sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1032 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1033 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1034 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1035 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1036 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1037 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1038 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1039 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1040 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1041 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1042 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1043 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1044 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1045 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1046 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1047 Vehicle Speed Sensor: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1048 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1049 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 1050 Vehicle Speed Sensor: Description and Operation The PCM uses a speed pulse input received from the Controller Anti-Lock Brake (CAB) and internal programming to decide what vehicle speed and distance messages are required. The PCM then sends the proper messages to the instrument cluster circuitry on the CCD data bus. The CAB uses an input from the rear wheel speed sensor and internal programming, which includes a programmable pinion factor to compensate for different axle gear ratios and tire sizes, to determine what speed pulse output is required. The CAB then sends the proper speed pulse to the PCM on a hard-wired circuit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Throttle Position Sensor: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1056 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1057 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1058 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1059 152 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1060 156 Revision to the Fuel System Rich test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1061 316 Revisions to the Throttle Position sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1062 620 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1063 622 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1064 Throttle Position Sensor: Locations Throttle Position Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1065 Throttle Position Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1066 Throttle Position Sensor: Description and Operation The TPS provides throttle position input signals to the Powertrain Control Module (PCM). This input signal is used to determine overdrive and converter clutch shift schedule and to select the proper governor curve. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1067 Throttle Position Sensor: Testing and Inspection The throttle position sensor (TPS) is used on diesel powered engines only when equipped with an automatic transmission and/or an Exhaust Gas Recirculation (EGR) system. If the TPS is to be replaced on a diesel engine, it must be tested/adjusted after replacement. REMOVAL 1. Disconnect electrical connector on bottom of TPS. 2. Remove two TPS mounting bolts. 3. Remove sensor from bracket. INSTALLATION 1. Position TPS to mounting bracket. The electrical connector should be facing downward. NOTE: The TPS is spring loaded. After positioning the TPS to its mounting bracket, rotate TPS on bracket in a counterclockwise direction until two bolt holes align. 2. Install and tighten two bolts. 3. Connect electrical connector on bottom of TPS. 4. Operate the throttle by hand to check for binding. 5. The TPS voltage must now be tested and (if necessary) adjusted. Refer to the following: THROTTLE POSITION SENSOR TESTING & ADJUSTMENT CAUTION: Before attempting to test TPS, verify linkage adjustment dimension. This dimension MUST be 126.5 mm (5.0 inches) BEFORE testing. For linkage adjustment procedures, refer to Throttle Linkage Adjustment-Diesel Engine. CAUTION: Before testing TPS, verify that engine is set at correct low idle speed. Refer to Idle Speed Adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1068 1. After confirming correct linkage adjustment and idle speed, proceed to the following: 2. Attach a paper clip into center terminal of TPS electrical connector. Do not remove connector from TPS for this test. 3. Attach positive lead of a voltmeter to this paper clip and negative lead to a good ground. 4. Turn ignition switch to ON position. Do not start engine. 5. The voltage at TPS center terminal should be 1.0 volt (+/- 0.2 volt) with linkage at idle position. At wide open throttle (WOT), output voltage must be 2.2-to-2.9 volts higher than at idle speed. If voltage is not correct, proceed to adjusting linkage. 6. The throttle lever rod connecting throttle lever to fuel injection pump lever is adjustable. To prevent damage to ends of linkage, attach locking-type pliers to flat located on throttle lever rod before loosening locknuts. 7. Loosen lever nut. This nut is close to the flat. 8. Unsnap lever socket from lever. 9. Slowly rotate the flat on linkage rod (lengthen or shorten) to achieve 1.0 volt (+/- 0.2 volts) on voltmeter with linkage in idle position. At wide open throttle (WOT), output voltage must be 2.2-to- 2.9 volts higher than at idle speed. DO NOT lengthen or shorten linkage rod more than 1 mm from dimension shown. If voltage requirements cannot be met by linkage adjustment (125.6 to 127.6 mm), replace TPS. 10. Tighten rod nut after adjustment. 11. With engine OFF, operate throttle from accelerator pedal and check for throttle lever action and binding. Be sure throttle lever stop is against low idle speed screw after throttle is released. 12. Be sure of wide open throttle (WOT) when accelerator pedal is pressed to the floor. This is checked by observing throttle lever breakover position. Proceed to the following: a. Key OFF and engine OFF for this test. b. Two people are needed for this test. From inside of vehicle, press accelerator pedal about half-way to floor. Movement of both throttle lever and throttle lever-to-injection pump lever linkage rod should be observed. c. Continue to press accelerator pedal to floor. If throttle lever breakover is operating correctly, the throttle lever-to-injection pump lever linkage rod should have stopped moving while throttle lever continues to move towards rear of vehicle. 13. Again, check and verify low idle speed. Adjust if necessary Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1069 Throttle Position Sensor: Service and Repair The throttle position sensor (TPS) is used on diesel powered engines only when equipped with an automatic transmission and/or an Exhaust Gas Recirculation (EGR) system. If the TPS is to be replaced on a diesel engine, it must be tested/adjusted after replacement. REMOVAL 1. Disconnect electrical connector on bottom of TPS. 2. Remove two TPS mounting bolts. 3. Remove sensor from bracket. INSTALLATION 1. Position TPS to mounting bracket. The electrical connector should be facing downward. NOTE: The TPS is spring loaded. After positioning the TPS to its mounting bracket, rotate TPS on bracket in a counterclockwise direction until two bolt holes align. 2. Install and tighten two bolts. 3. Connect electrical connector on bottom of TPS. 4. Operate the throttle by hand to check for binding. 5. The TPS voltage must now be tested and (if necessary) adjusted. Refer to the following: THROTTLE POSITION SENSOR TESTING & ADJUSTMENT CAUTION: Before attempting to test TPS, verify linkage adjustment dimension. This dimension MUST be 126.5 mm (5.0 inches) BEFORE testing. For linkage adjustment procedures, refer to Throttle Linkage Adjustment-Diesel Engine. CAUTION: Before testing TPS, verify that engine is set at correct low idle speed. Refer to Idle Speed Adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1070 1. After confirming correct linkage adjustment and idle speed, proceed to the following: 2. Attach a paper clip into center terminal of TPS electrical connector. Do not remove connector from TPS for this test. 3. Attach positive lead of a voltmeter to this paper clip and negative lead to a good ground. 4. Turn ignition switch to ON position. Do not start engine. 5. The voltage at TPS center terminal should be 1.0 volt (+/- 0.2 volt) with linkage at idle position. At wide open throttle (WOT), output voltage must be 2.2-to-2.9 volts higher than at idle speed. If voltage is not correct, proceed to adjusting linkage. 6. The throttle lever rod connecting throttle lever to fuel injection pump lever is adjustable. To prevent damage to ends of linkage, attach locking-type pliers to flat located on throttle lever rod before loosening locknuts. 7. Loosen lever nut. This nut is close to the flat. 8. Unsnap lever socket from lever. 9. Slowly rotate the flat on linkage rod (lengthen or shorten) to achieve 1.0 volt (+/- 0.2 volts) on voltmeter with linkage in idle position. At wide open throttle (WOT), output voltage must be 2.2-to- 2.9 volts higher than at idle speed. DO NOT lengthen or shorten linkage rod more than 1 mm from dimension shown. If voltage requirements cannot be met by linkage adjustment (125.6 to 127.6 mm), replace TPS. 10. Tighten rod nut after adjustment. 11. With engine OFF, operate throttle from accelerator pedal and check for throttle lever action and binding. Be sure throttle lever stop is against low idle speed screw after throttle is released. 12. Be sure of wide open throttle (WOT) when accelerator pedal is pressed to the floor. This is checked by observing throttle lever breakover position. Proceed to the following: a. Key OFF and engine OFF for this test. b. Two people are needed for this test. From inside of vehicle, press accelerator pedal about half-way to floor. Movement of both throttle lever and throttle lever-to-injection pump lever linkage rod should be observed. c. Continue to press accelerator pedal to floor. If throttle lever breakover is operating correctly, the throttle lever-to-injection pump lever linkage rod should have stopped moving while throttle lever continues to move towards rear of vehicle. 13. Again, check and verify low idle speed. Adjust if necessary Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1076 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. Key Cylinder Removal 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. Ignition Switch Removal 1. Remove key lock cylinder. Refer to previous steps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1077 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On- SDMTR10 or equivalent) to remove screws. Ignition Switch And Halo Lamp Connectors 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. Ignition Switch And Key Cylinder Installation If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In RUN Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1078 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1079 Ignition Switch View From Column Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1080 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 N.m ± 0.5 N.m (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 N.m (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches NUMBER: 08-025-01 GROUP: Electrical DATE: Nov. 23, 2001 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS, PARTS, AND 2001 MODEL YEAR PROCEDURES. NOTE: THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS. SUBJECT: Airbag On-Off Switches MODELS: 1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - **2001** (AB) Ram Van/Wagon 1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) Lebaron Coupe/Convertible 1994 - **2001** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - **2001** (BR/BE) Ram Pickup 1995 - 1996 (B7) Stealth 1998 - **2001** (DN) Durango 1995 - 2000 (FJ) Avenger/Sebring/Talon 1995 - 2000 (JA) Breeze/Cirrus/Stratus **2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - **2001** (PL) Neon 1997 (PR) Prowler **2001 (PT) PT Cruiser** **2001** (RS) Town & Country/Caravan/Voyager Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1086 1996 - 1997 (SR) Viper **2001 - 2002 (ST) Sebring Coupe/Stratus Coupe** 1997 - 2001** (TJ) Wrangler 1999 - **2001** (WJ) Grand Cherokee 1997 - **2001** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. NOTE: **SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.** DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. NOTE: FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001 CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE AIRBAG KIT. **FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS, AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N 05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.** Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1087 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1088 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1089 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1090 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1091 PARTS REQUIRED: NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have~ 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1092 Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch Availibility NO: 08-17-98 Rev. C GROUP: Electrical DATE: Dec. 30, 1998 SUBJECT: Airbag On-Off Switches THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**. MODELS: **1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan** 1995 - **1999** (AB) Ram Van/Wagon **1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon** 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/Convertible 1994 -**1999** (AN) Dakota 1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1991 - 1995 (AS) Town & Country/Caravan/Voyager **1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue** 1994 - **1999** (BR) Ram Pickup **1995 - 1996 (B7) Stealth** 1998 - **1999** (DN) Durango **1995 - 1999 (FJ) Avenger/Sebring/Talon** 1995 - **1999** (JA) Breeze/Cirrus/Stratus 1996 - **1999** (JX) Sebring Convertible 1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - **1999** (NS) Town & Country/Caravan/ Voyager 1995 - **1999** (PL) Neon 1996 - 1997 (SR) Viper 1997 - **1999** (TJ) Wrangler 1997 - **1999** (XJ) Cherokee 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed above. Other applicable passenger vehicles will be announced as soon as the switches are available. The switches are packaged in a kit containing all necessary parts (except as indicated) and a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA authorization letter. For more information concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you (dealer) to install these switches when the customer is interested in doing so and has the necessary NHTSA authorization. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1093 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1094 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1095 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1096 PARTS REQUIRED: Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1097 NOTE: SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES. DEACTIVATION/DOCUMENTATION PROCEDURE: 1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner must present to you an "Authorization Form" from the U.S. Department of Transportation National Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle identification number. The authorization applies only to the vehicle identified and not to other vehicles that the owner may have. 2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for your records and make a copy for the vehicle owner. 3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making copies for the owner's and your records. NOTE: ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 1098 POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1099 Passenger Airbag Disable Switch Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1100 Air Bag Deactivation Switch: Diagrams Passenger Airbag Disable Switch Connector Passenger Airbag Disable Switch (Pads) Connector (Harness Side) Passenger Airbag Disable Switch (pads) 2-Way Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1101 Air Bag Deactivation Switch: Description and Operation SYSTEM OPERATION Passenger Airbag Disarm Switch A Passenger Airbag Disarm Switch (PADS) located on the instrument panel allows the passenger side airbag module to be disarmed when certain child restraint devices are being used in the right front seating position. The PADS is equipped with a key cylinder so that the switch position can only be changed using an ignition key when the ignition switch is in the On position and the passenger side airbag is disarmed, a Light-Emitting Diode (LED) illuminates an "Off" indicator lamp on the face plate of the switch. To actuate the PADS switch, insert the ignition key in the switch key cylinder. The PADS key cylinder is then rotated with the ignition key to its clockwise stop (the key cylinder slot will be aligned with the Off indicator lamp) to disarm the passenger side air- bag. When the PADS key cylinder is rotated with the ignition key to its counterclockwise stop (the key cylinder slot will be in a vertical position), the Off indicator lamp will be extinguished and the passenger side airbag module will once again be armed. WARNING: THE KEY MUST ALWAYS BE REMOVED FROM THE PASSENGER AIRBAG DISARM SWITCH KEY CYLINDER AFTER THE SWITCH HAS BEEN USED. NEVER LEAVE A KEY IN THE PADS KEY CYLINDER. The PADS cannot be adjusted or repaired and, if faulty or damaged, the PADS unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1102 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. if the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. 2. Remove the cluster bezel from the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/Instrument Panel/Cluster Bezel Replacement for the procedures. 3. Remove the glove box from the instrument panel. Refer to Body and Frame/Glove Compartment/Glove Box Replacement for the procedures. Switch Mounting Plate Remove/Install 4. Remove the three screws that secure the switch mounting plate to the instrument panel. 5. If the vehicle is equipped with fog lamps, pull the switch mounting plate away from the instrument panel far enough to access and unplug the wire harness connector from the back of the fog lamp switch. Passenger Airbag Disarm Switch Connectors 6. Reach through the glove box opening to access and unplug the two passenger airbag disarm switch wire harness connectors, located on a bracket on the inboard glove box opening reinforcement. 7. Remove the switch mounting plate and passenger airbag disarm switch from the instrument panel as a unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Technical Service Bulletins > Page 1103 Passenger Airbag Disarm Switch Remove/Install 8. Remove the three screws that secure the passenger airbag disarm switch to the switch mounting plate. 9. Remove the passenger airbag disarm switch from the switch mounting plate. 10. Reverse the removal procedures to install. Tighten the mounting screws to 2.2 N.m (20 in. lbs.). 11. Do not connect the battery negative cable at this time. See Airbag System in the Diagnosis and Testing for the proper procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations Airbag Control Module (ACM) The airbag impact and safing sensors are located inside the airbag control module. The airbag control module is located under the center of the instrument panel and is attached to the center instrument panel support bracket. The airbag impact and safing sensors are integral to the airbag control module and are not separately serviceable. If found to be defective, the airbag control module must be replaced as a whole unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1107 Impact Sensor: Description and Operation Impact and Safing Sensors One electronic impact sensor is used in this airbag system. The impact sensor is an accelerometer that senses the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The impact sensor is calibrated for the specific vehicle, and is only serviced as a unit with the ACM. A pre-programmed decision algorithm in the ACM microprocessor determines when the deceleration rate as signaled by the impact sensor indicates an impact that is severe enough to require airbag system protection. When the programmed conditions are met, the ACM sends an electrical signal to deploy the airbags. In addition to the electronic impact sensor, there is an electromechanical sensor within the ACM called a safing sensor. The safing sensor is a normally open series switch located in the airbag deployment circuit of the ACM. This sensor detects impact energy of a lesser magnitude than the electronic impact sensor, and must be closed in order for the airbags to deploy. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1108 Impact Sensor: Service and Repair The impact and safing sensors are integral to the airbag control module and are not separately serviceable. If the sensors or airbag control module is found to be defective, the airbag control module must be replaced as a complete unit. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations Battery Temp Sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1113 Battery Temperature Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1114 Battery Temperature Sensor: Service Precautions WARNING: TO PROTECT THE HANDS FROM BATTERY ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE WORN WHEN REMOVING OR SERVICING A BATTERY. SAFETY GLASSES ALSO SHOULD BE WORN . Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Locations > Page 1115 Battery Temperature Sensor: Description and Operation SYSTEM OPERATION The battery temperature sensor is used to determine the battery temperature and control battery charging rate. This temperature data, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Testing Battery Temperature Sensor: Testing and Inspection Testing To perform a complete test of this sensor and its circuitry, refer to the appropriate Powertrain Diagnostic Procedures. To test the sensor only, refer to the following: Battery Temperature Sensor Location 1. The sensor is located under the battery and is attached (snapped into) the battery tray. On models equipped with a diesel engine (dual batteries), only one sensor is used. Location is under battery on drivers side of vehicle. A two-wire pigtail harness is attached directly to the sensor. The opposite end of this harness connects the sensor to the engine wiring harness. 2. Disconnect the two-wire pigtail harness from the engine harness. 3. Attach ohmmeter leads to the wire terminals of the pigtail harness. 4. At room temperature of 25° C (75-80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms should be observed. 5. If reading is above or below the specification, replace the sensor. 6. Refer to the Replacement for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Testing and Inspection > Page 1118 Battery Temperature Sensor: Service and Repair Battery Temperature Sensor Location The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray On models equipped with a diesel engine (dual batteries), only one sensor is used. The sensor is located under the battery on drivers side of vehicle. REMOVAL 1. Remove battery. Refer to Battery for procedures. 2. Disconnect sensor pigtail harness from engine wire harness. 3. Pry sensor straight up from battery tray mounting hole. INSTALLATION 1. Feed pigtail harness through mounting hole in top of battery tray and press sensor into top of tray (snaps in). 2. Connect pigtail harness. 3. Install battery. Refer to Battery for procedures. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Description and Operation Clutch Switch: Description and Operation Clutch Pedal Position (Interlock) Switch All BR models are equipped with a clutch pedal position switch. The switch is in circuit with the starter relay and is mounted on the clutch master cylinder push rod. The switch is actuated by clutch pedal movement. The clutch pedal must be fully depressed in order to start the engine. The position switch is an integral part of the clutch master cylinder push rod and is not serviced separately. Refer to Wiring Diagrams for component locations and circuit information. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation SYSTEM OPERATION The ignition switch is located on the steering column. The Key-In-Switch is located in the ignition switch module. For removal/installation of either the key lock cylinder or ignition switch, refer to Ignition Switch and Key Cylinder Replacement. On vehicles equipped with an automatic transmission, a cable connects an interlock device within the steering column assembly to the transmission floor shift lever. This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position. The interlock device is not serviceable. If repair is necessary, the steering column assembly must be replaced. The shifter interlock cable can be adjusted or replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1126 Ignition Switch Lock Cylinder: Service and Repair The ignition key must be in the key cylinder for cylinder removal. Key Cylinder Removal 1. Disconnect negative cable from battery. 2. If equipped with tilt column, remove tilt lever by turning it counterclockwise. Shroud Removal/Installation - Typical 3. Remove upper and lower covers (shrouds) from steering column. 4. If equipped with automatic transmission, place shifter in PARK position. Retaining Pin 5. A retaining pin is located at side of key cylinder assembly a. Rotate key to RUN position. b. Press in on retaining pin while pulling key cylinder from ignition switch. Ignition Switch Removal 1. Remove key lock cylinder. Refer to previous steps. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1127 Switch Mounting Screws 2. Remove 3 ignition switch mounting screws. Use tamper proof torx bit (Snap-On- SDMTR10 or equivalent) to remove screws. Ignition Switch And Halo Lamp Connectors 3. Gently pull switch away from column. Release connector locks on 7-terminal wiring connector at ignition switch and remove connector. 4. Release connector lock on 4-terminal halo lamp wiring connector and remove connector. Ignition Switch And Key Cylinder Installation If installing ignition key lock cylinder only, proceed to following steps 2, 3 and 4. Also refer to following steps 12 through 18. If installing both switch and key cylinder, refer to steps 1 through 18. Flag In RUN Position Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1128 Key Cylinder - Rear View 1. Rotate flag on rear of ignition switch until in RUN position. This step must be done to allow tang on key cylinder to fit into slots within ignition switch. Installing Key Cylinder Into Switch 2. With key into ignition key cylinder, rotate key clockwise until retaining pin can be depressed. 3. Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot. Push key cylinder into switch until retaining pin engages. After pin engages, rotate key to OFF or LOCK position. 4. Check for proper retention of key cylinder by attempting to pull cylinder from switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1129 Ignition Switch View From Column Park Lock Linkage - Automatic Transmission - Typical 5. Automatic Transmission Only: Before attaching ignition switch to steering column, the transmission shifter must be in PARK position. The park lock dowel pin on rear of ignition switch must also be properly indexed into the park lock linkage before installing switch. 6. The flag at rear of ignition switch must be properly indexed into steering column before installing switch. This flag is used to operate the steering wheel lock lever in steering column. This lever allows steering wheel position to be locked when key switch is in LOCK position. 7. Place ignition switch in LOCK position. The switch is in the LOCK position when column lock flag is parallel to ignition switch terminals. 8. Automatic Transmission Only: Apply a light coating of grease to park lock dowel pin and park lock slider linkage. Before installing switch, push the park lock slider linkage forward until it bottoms. Do a final positioning by pulling it rearward about one-quarter inch. 9. Apply a light coating of grease to both column lock flag and shaft at end of flag. 10. Place ignition switch into openings on steering column. a. Automatic Transmission Only: Be sure park lock dowel pin on rear of ignition switch enters slot in park lock slider linkage. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1130 Steering Wheel Lock Lever b. Be sure flag on rear of switch is positioned above steering wheel lock lever. c. Align dowel pins on rear of switch into holes on side of steering column. d. Install 3 ignition switch mounting screws. Tighten screws to 3 N.m ± 0.5 N.m (26 in. lbs. ± 4 in. lbs.) torque. 11. Connect electrical connectors to ignition switch and halo lamp. Make sure that switch locking tabs are fully seated in wiring connectors. 12. Install steering column covers (shrouds). Tighten screws to 2 N.m (17 in. lbs.) torque. 13. Install tilt column lever (if equipped). 14. Connect negative cable to battery 15. Check for proper operation of halo light. 16. Automatic Transmission Only: Shifter should lock in PARK position when key is in LOCK position (if equipped with shift lock device). Shifter should unlock when key rotated to ON position. 17. Check for proper operation of ignition switch in ACCESSORY, LOCK, OFF, ON, RUN, and START positions. 18. Steering wheel should lock when key is in LOCK position. Rotate steering wheel to verify. Steering wheel should unlock when key is rotated to ON position. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications Neutral Safety Switch: Specifications Switch .................................................................................................................................................. ..................................................... 34 Nm (25 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1134 Neutral Safety Switch: Locations Transmission Solenoid 8-way Connector, Output Speed Sensor, Vehicle Speed Sensor (4-Wheel Drive), Vehicle Speed Sensor (2-Wheel Drive), Park/Neutral Switch Solenoid Case Connector, Park/Neutral Position Switch Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1135 Park/Neutral Position Switch Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1136 Neutral Safety Switch: Testing and Inspection GENERAL INFORMATION The center terminal of the park/neutral position switch is the starter-circuit terminal. It provides the ground for the starter solenoid circuit through the selector lever in PARK and NEUTRAL positions only. The outer terminals on the switch are for the backup lamp circuit. SWITCH TEST To test the switch, remove the wiring connector. Test for continuity between the center terminal and the transmission case. Continuity should exist only when the transmission is in PARK or NEUTRAL. Shift the transmission into REVERSE and test continuity at the switch outer terminals. Continuity should exist only when the transmission is in REVERSE. Continuity should not exist between the outer terminals and the case. Check gearshift linkage adjustment before replacing a switch that tests faulty. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Specifications > Page 1137 Neutral Safety Switch: Service and Repair REMOVAL 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. INSTALLATION Park/Neutral Position Switch 1. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 2. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 3. Test continuity of new switch with 12V test lamp. 4. Connect switch wires and lower vehicle. 5. Top off transmission fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1143 Overdrive Switch Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1144 Overdrive Switch: Description and Operation The overdrive OFF (control) switch is located in the instrument panel. The switch is a momentary contact device that signals the PCM to toggle current status of the overdrive function. At key-on, overdrive operation is allowed. Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off. The overdrive OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in this position to energize the solenoid and allow a 3-4 upshift. The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position, or when illuminated by the transmission control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1148 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch 1. Raise vehicle and position drain pan under switch. 2. Disconnect switch wires. 3. Remove switch from case. 4. Move shift lever to Park and Neutral positions. Verify that switch operating lever fingers are centered in switch opening in case. 5. Install new seal on switch and install switch in case. Tighten switch to 34 Nm (25 ft. lbs.) torque. 6. Test continuity of new switch with 12V test lamp. 7. Connect switch wires and lower vehicle. 8. Top off transmission fluid level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Output Speed Sensor, Vehicle Speed Sensor (4-Wheel Drive), Vehicle Speed Sensor (2-Wheel Drive), Park/Neutral Switch, Transmission Solenoid 8-Way Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1152 Output Speed Sensor Connector Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1153 Transmission Speed Sensor: Description and Operation Transmission Output Speed Sensor The speed sensor is located in the overdrive gear case. The sensor is positioned over the park gear and monitors transmission output shaft rotating speed. Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face. Input signals from the sensor are sent to the transmission control module for processing. The vehicle speed sensor also serves as a backup for the transmission speed sensor. Signals from this sensor are shared with the powertrain control module. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Transmission Temperature Sensor/Switch: Locations Governor Pressure Sensor, Transmission Temperature Sensor, Governor Pressure Solenoid, Governor The transmission temperature sensor is located in the transmission solenoid assembly in the valve body. The governor pressure sender and the transmission fluid temperature thermistor are separate sensors in the same component. This component is attached to the governor body in the solenoid assembly of the valve body. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 1157 Transmission Temperature Sensor/Switch: Description and Operation Transmission fluid temperature readings are supplied to the transmission control module by the thermistor. The temperature readings are used to control engagement of the fourth gear overdrive clutch, the converter clutch, and governor pressure. Normal resistance value for the thermistor at room temperature is approximately 1000 ohms. The PCM prevents engagement of the converter clutch and overdrive clutch, when fluid temperature is below approximately 10° C (50° F). If fluid temperature exceeds 126° C (260° F), the Powertrain Control Module (PCM) causes a 4-3 downshift and engage the converter clutch. Engagement is according to the third gear converter clutch engagement schedule. The overdrive OFF lamp in the instrument panel illuminates when the shift back to third occurs. The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110° C (230° F). The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Lockout Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1163 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1164 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1165 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1166 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1167 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1168 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1169 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1170 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1171 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1172 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1173 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1174 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1175 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1176 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1177 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1178 Power Window Lockout Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1179 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Lockout Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1180 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1185 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1186 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1187 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1188 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1189 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1190 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1191 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1192 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1193 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1194 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1195 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1196 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1197 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1198 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1199 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1200 Power Window Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1201 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1202 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1203 Power Window Switch: Description and Operation SYSTEM OPERATION The power windows are controlled by two-way switches integral to the power window and lock switch and bezel unit on the trim panel of each front door. A second power window switch in the driver side switch and bezel unit allows the driver to control the passenger side window. A Light-Emitting Diode (LED) in the paddle of each switch is illuminated whenever the ignition switch is in the On position. The power window switches control the battery and ground feeds to the power window motors. The passenger side power window switch receives a ground feed through the driver side power window switch for operating the passenger side power window motor. The power window and lock switch and bezel unit cannot be repaired and, if faulty or damaged, the entire switch and bezel unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1204 Power Window Switch: Testing and Inspection The Light-Emitting Diode LED. illumination lamps for all of the power window and lock switch and bezel unit switch paddles receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in either or both power window and lock switch and bezel units and the power windows are inoperative, perform the diagnosis for Power Window System. If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch and bezel unit with the inoperative LEDs. is faulty and must be replaced. 1. Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty circuit breaker. 2. Turn the ignition switch to the On position. Check for battery voltage at the circuit breaker in the junction block. If OK, turn the ignition switch to the Off position and go to Step 3. If not OK, repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window and lock switch and bezel unit from the door trim panel. Unplug the wire harness connector from the switch and bezel unit. Power Window Switch Continuity - Driver Side Power Window Switch Continuity - Passenger Side 4. Test the power window switch continuity. See the Power Window Switch Continuity charts to determine if the continuity is correct in the Neutral, Up and Down switch positions. If OK, see Power Window Motor in the Diagnosis and Testing. If not OK, replace the faulty switch. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1205 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window And Lock Switch And Bezel Unit Remove/Install 2. Using a wide flat-bladed tool such as a trim stick, gently pry the upper edge of the switch bezel to release the retainer that secures the switch bezel to the door trim panel opening. 3. Pull the switch and bezel unit away from the door trim panel opening far enough to access and unplug the wire harness connector. 4. Remove the power window and lock switch and bezel unit from the door trim panel. 5. Reverse the removal procedures to install. When installing the switch and bezel unit to the door trim panel opening, insert the rear of the bezel into the opening, then push down on the front of the bezel until the retaining tab snaps into place. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation Washer Fluid Level Switch: Description and Operation SYSTEM OPERATION Washer Fluid Level Sensor The washer fluid level sensor is mounted on the inboard side of the reservoir above the washer pump. A barbed nipple on the sensor is press-fit into a rubber grommet seal installed in a hole in the side of the reservoir. When the fluid level in the reservoir falls below the pivoting float on the sensor, the float changes position and closes the internal switch contacts of the sensor. Refer to Low Washer Fluid Warning Lamp in the Diagnosis and Testing of Instrument Panel Systems for diagnosis of the low washer fluid warning lamp and circuit, including the sensor. The washer fluid level sensor cannot be repaired. If faulty or damaged, the sensor unit must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Page 1210 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Unplug the wire harness connector from the washer pump. 3. Remove the washer supply hose from the washer pump and drain the washer fluid from the reservoir into a clean container for reuse. NOTE: The pivoting float of the washer fluid sensor must be in a horizontal position within the reservoir in order to be removed. With the reservoir empty and held in an upright position, the pivoting float will orient itself to the horizontal position when the sensor connector is pointed straight downwards. 4. Using a trim stick or another suitable wide flat-bladed tool, gently pry the washer fluid level sensor out of the rubber grommet seal. Care must be taken not to damage the reservoir. 5. Remove the rubber grommet seal from the reservoir and discard. 6. Reverse the removal procedures to install. Always use a new rubber grommet seal on the reservoir. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1215 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1216 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1217 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1218 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1219 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1220 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1221 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1222 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1223 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1224 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1225 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1226 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1227 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1228 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1229 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1230 Windshield Washer Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1231 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1232 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1233 Windshield Washer Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1234 Windshield Washer Switch: Testing and Inspection See Wiper System and/or Washer System in the Diagnosis and Testing before testing the multi-function switch. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Page 1235 Windshield Washer Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch mounting screws - 2 N.m (17 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Introduction General Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1240 General Information Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around a component indicates that the component being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Circuit Function Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1241 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Circuit Information Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1242 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gauge of wire, and color. Connector Information CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers. - Connectors located on the instrument panel harness are C200 series numbers. - Connectors located on the body harness are C300 series numbers. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1243 - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connector. Component Identification Component connectors are identified by the component name instead of a number. Connector Identification Multiple connectors on a component use a C1, C2, etc. identifier. Electrostatic Discharge (ESD) Sensitive Devices Electrostatic Discharge Symbol All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part, especially after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from its protective packing until it is time to install the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. Fasteners Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1244 Shock Tower To Spring Minimum Clearance Area CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front strut tower in the area shown in for the installation of any metal fasteners into the strut tower. Because of the minimum clearance in this area , installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts catalog. Fuses CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected. Notes, Cautions and Warnings Additional important information is presented in three ways: Notes, Cautions, and Warnings. NOTES are used to help describe how switches or components operate to complete a particular circuit. They are also used to indicate different conditions that may appear on the vehicle. For example, an up-to and after condition. CAUTIONS are used to indicate information that could prevent making an error that may damage the vehicle. WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING. Positive Temperature Coefficient Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's act like a solid state fuse. They are located in the Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1245 junction block, and are used to protect such items as: power door lock motors, power windows, and various engine solenoids. Positive Temperature Coefficient Symbol A special symbol is used to identify these in the wiring diagrams. Section Identification Wiring Diagram Section Identification The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Symbols Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1246 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Take-Outs The abbreviation T/O is used in the component location to indicate a point at which the wiring harness branches out to a component. How to Find System & Component Diagrams When trying to find the diagram for a specific component or system, use the Group Index information or the Alphabetic Index to Wiring Diagrams under Electrical Whenever a reference exists to another sheet or figure, find the corresponding diagram using the Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number for the subsequent diagram will match a listed group shown. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1247 Connector and Terminal Replacement 1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals. 5. Remove 1 inch of insulation from each wire on the harness side. Stagger Cutting Wires (Typical) 6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was done on the harness side of the repair. Allow extra length for soldered connections. Check that the overall length is the same as the original. 7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair 9. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 10. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17. Connect the battery and test all affected systems. Connector Replacement Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1248 1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating half/component. Connector Locking Wedge 3. Remove the connector locking wedge, if required. Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired connector, if required. 9. Connect the connector to its mating half/component. 10. Connect the battery and test all affected systems. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1249 Diode Replacement Diode Identification 1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect the battery and test affected systems. Terminal Replacement 1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating half/component. Connnector Locking Wedge Tab (Typical) 3. Remove the connector locking wedge, if required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1250 Terminal Removal Terminal Removal Using Special Tool 4. Position the connector locking finger away from the terminal using the proper pick from Special Tool Kit 6680. Pull on the wire to remove the terminal from the connector. 5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. Wire Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1251 10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12. Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all affected systems. Terminal/Connector Repair-Molex Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Molex Connector Repair 3. Insert the terminal releasing special tool 6742 into the terminal end of the connector. Using Special Tool 6742 4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove it from the connector. 6. Repair or replace the connector or terminal, as necessary. Terminal/Connector Repair-Thomas and Betts Connectors 1. Disconnect the battery. 2. Disconnect the connector from its mating half/component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1252 Thomas And Betts Connector Lock Release Tabs 3. Push in the two lock tabs on the side of the connector. Removing Wire Terminal 4. Insert the probe end of Special Tool 6934 into the back of the connector cavity. 5. Grasp the wire and Special Tool 6934 and slowly remove the wire and terminal from the connector. 6. Repair or replace the terminal. 7. Install the wire and terminal in the connector. Fully seat the terminal in the connector. Single Lock Tab 8. Push in the single lock tab on the side of the connector. Wiring Repair Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1253 Wire Repair When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. 1. Disconnect the battery negative cable. 2. Remove 1 inch of insulation from each end of the wire. 3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. 4. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 5. Push the two ends of wire together until the strands of wire are close to the insulation (Example 2). 6. Twist the wires together (Example 3). 7. Solder the connection together using rosin core solder only. Do not use acid core solder. 8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. 9. Secure the wire to the existing ones to prevent chafing or damage to the insulation. 10. Connect the battery and test all affected systems. Special Tools Probing Tool Package 6807 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1254 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1255 Wiper Switch: Diagnostic Aids Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked in position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt and moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation covering. - Wiring broken inside of the insulation Troubleshooting Tests Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the circuit. Also refer to Troubleshooting Wiring Problems section. Testing For Voltage Testing For Voltage 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1256 Testing For Continuity Testing For Continuity 1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the test light glows, there is a short-to-ground in that general area of the wiring harness. Testing For A Short-to-ground On Fuses Powering Several Loads 1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the circuit with the short-to-ground has been isolated. Testing For Voltage Drop Testing For Voltage Drop 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch or component. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1257 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit, there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking voltages in these circuits, use a meter with a 10 megohm or greater impedance. - Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low or no resistance in a circuit can mean good continuity or a shorted circuit. CAUTION: Most of the electrical components used in today's vehicle are solid state. When checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the vehicle electrical system can cause damage to the equipment and provide false readings. Probing Tool - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem. 6. Verify proper operation. For this step check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1258 Wiper Switch: Description and Operation SYSTEM OPERATION Multi-Function Switch The windshield wiper and washer switches are contained in the multi-function switch assembly. The multi-function switch assembly is secured to the left side of the steering column. A knob on the end of the multi-function switch stalk is rotated to select the desired wiper speed or intermittent wipe delay, or depressed toward the steering column to activate the washer system. The multi-function switch contains circuitry for the following functions: Turn signals - Hazard warning - Headlamp beam selection - Headlamp optical horn - Windshield wipers - Windshield washers. The information contained addresses only the switch functions for the windshield wiper and washer systems. However, the multi-function switch cannot be repaired. If any function of the multi-function switch is faulty, or if the switch is damaged, the entire switch assembly must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1259 Wiper Switch: Testing and Inspection See Wiper System and/or Washer System in the Diagnosis and Testing before testing the multi-function switch. For additional testing and inspection information please refer to Powertrain Management/Computers and Control Systems/ See: Body and Frame/Body Control Systems/Central Timer Module WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Unplug the multi-function switch wire harness connector from the multi-function switch. Multi-Function Switch Continuity 3. Using an ohmmeter, perform the switch continuity checks at the switch terminals as shown in the Multi-Function Switch Continuity chart. 4. If the switch fails any of the continuity checks, replace the faulty switch. If the switch is OK, repair the wiper system and/or washer system wire harness circuits as required. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1260 Wiper Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. If the vehicle is so equipped, remove the tilt steering column lever. Steering Column Shrouds Remove/Install - Typical 3. Remove both the upper and lower shrouds from the steering column. 4. Remove the lower fixed column shroud. Multifunction Switch 5. Move the upper fixed column shroud far enough to access the rear of the multi-function switch. 6. Remove the tamper proof mounting screws (a Snap On tamper proof torx bit TTXR20B2 or equivalent is required) that secure the multi-function switch to the steering column. 7. Gently pull the switch away from the steering column far enough to access and remove the multi-function switch wire harness connector screw. 8. Unplug the wire harness connector from the multi-function switch. 9. Reverse the removal procedures to install. Tighten the fasteners as follows: - Multi-function switch wire harness connector screw - 2 N.m (17 in. lbs.) - Multi-function switch mounting screws - 2 N.m (17 in. lbs.). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Pick-Up Alignment: Specifications Pick-Up CASTER: With a GVW of 8,800 lbs. and a Wheel Base of 134.7 inches: Preferred ........................................... .............................................................................................................................................................. ......... +3.10° Range ............................................................................................................................ .......................................................................................... ± 1.00° With a GVW of 8,800 lbs. and a Wheel Base of 138.7 inches: Preferred ........................................... .............................................................................................................................................................. ......... +3.15° Range ............................................................................................................................ .......................................................................................... ± 1.00° With a GVW of 8,800 lbs. and a Wheel Base of 154.7 inches: Preferred ........................................... .............................................................................................................................................................. ......... +3.25° Range ............................................................................................................................ .......................................................................................... ± 1.00° CAMBER: Not Set TOTAL TOE-IN: Preferred .............................................................................................................................................. .................................................................... +0.10° Range ................................................................. ..................................................................................................................................................... ± 0.10° CROSS CASTER: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.5° CROSS CAMBER: Not Set THRUST ANGLE: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.4° Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Pick-Up > Page 1266 Alignment: Specifications Cab-Chassis NOTE: To determine correct caster alignment angle for Cab-Chassis vehicles the following procedure must be performed. CASTER: Chassis Measurement 1. Take a height measurement to the center of the front gauge hole in the frame. Take another measurement to the center of the rear spring hanger bolt. Take these measurements on both sides of the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Pick-Up > Page 1267 Corrected Caster Chart Cab-Chassis 2. Subtract the front measurement from the rear measurement and use the average between the right and left side. Use this number (caster correlation value) with the corrected caster chart to obtain the preferred caster angle. CAMBER: Not Set TOTAL TOE-IN: Preferred .............................................................................................................................................. .................................................................... +0.10° Range ................................................................. ..................................................................................................................................................... ± 0.10° CROSS CASTER: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.5° CROSS CAMBER: Not Set THRUST ANGLE: Preferred .............................................................................................................................................. ........................................................................... 0° Range ................................................................. ....................................................................................................................................................... ± 0.4° Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1268 Alignment: Description and Operation GENERAL INFORMATION Wheel alignment involves the correct positioning of the wheel in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to maximize tire wear. The most important measurements of an alignment are caster, camber and toe position. Caster - is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle rearward provides positive caster. Tilting the top of the knuckle forward provides negative caster. Caster is a directional stability angle which enables the front wheels to return to a straight ahead position after turns. Camber - is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. Wheel Toe Position - is the difference between the leading inside edges and trailing inside edges of the front tires. Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment. CAUTION: Do not attempt to modify any suspension or steering components by heating and bending. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1269 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Steering and Suspension/System Diagnosis for additional information. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear or adjustment. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement Alignment: Service and Repair Cab and Chassis Caster Correction Measurement NOTE: To determine the correct caster alignment angle for Cab-Chassis vehicles the following procedure must be performed. CAB-CHASSIS CASTER CORRECTION MEASUREMENT 1. Take a height measurement to the center of the front gauge hole in the frame. Take another measurement to the center of the rear spring hanger bolt. Take these measurements on both sides of the vehicle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement > Page 1272 Corrected Caster Chart Cab-Chassis 2. Subtract the front measurement from the rear measurement and use the average between the right and left side. Use this number with the Caster Correction Chart to obtain the preferred caster angle. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Cab and Chassis Caster Correction Measurement > Page 1273 Alignment: Service and Repair Camber, Caster and Toe Adjustment GENERAL INFORMATION Before each alignment reading the vehicle should be jounced (rear first, then front). Grasp each bumper at the center and jounce the vehicle up and down several times. Always release the bumper in the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION. Camber: The wheel camber angle is preset and is not adjustable. Caster: Check the caster of the front axle for correct angle. Be sure the axle is not bent or twisted. Road test the vehicle and make left and right turn. Observe the steering wheel return-to-center position. Low caster will cause poor steering wheel returnability. Caster can be adjusted by rotating the cams on the lower suspension arm. Toe Position: The wheel toe position adjustment should be the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Center and Secure the steering wheel and turn off engine. 2. Loosen the adjustment sleeve clamp bolts. Alignment Bar/Drag Link Adjustment CAUTION: Do not loosen/move alignment bar or alignment bar clamp. The bar is used as a locator for the adjuster clamps. This prevents adjuster clamp interference with the steering damper. 3. Adjust the right wheel toe position with the drag link. Turn the sleeve until the right wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 4. Adjust left wheel toe position with tie rod at left knuckle. Turn the sleeve until the left wheel is at the correct TOE-IN position. Position clamp bolts to their original position and tighten to specifications. Make sure the toe setting does not change during clamp tightening. 5. Verify the right toe setting. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Gauge Adapter - Usage Fuel Pressure: Technical Service Bulletins Fuel Pressure Gauge Adapter - Usage NO: 14-03-98 GROUP: Fuel DATE: May 1, 1998 SUBJECT: Fuel Pressure Gauge Adapter Usage MODELS: 1996 - 1998 (AB) Ram Van 1996 - 1998 (AN) Dakota 1996 - 1998 (BR/BE) Ram Truck 1998 (DN) Durango 1996 - 1998 (XJ) Cherokee 1996 - 1998 (ZJ) Grand Cherokee 1996 - 1998 (ZG) Grand Cherokee (International Markets) DISCUSSION: Currently, four different fuel pressure adapters are required, depending on application, to attach a fuel gauge for pressure testing. The matrix lists the adapter part numbers and their application. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1279 Fuel Pressure: Specifications Fuel Transfer (Lift) Pump Pressure At idle ................................................................................................................................................... .................................. 117 - 152 kPa (17 - 22 psi) At rated speed (2500 rpm) ...................................................................................................................................................... 172 - 207 kPa (25 - 30 psi) Fuel Injector "Pop Off" Pressure Using injector tester ............................................................................................................................. ............................................. 23,400 - 26,800 kPa .............................................................................................................................................................. ................... (234 - 268 bars) ............................................................................................................... ............................................................... (3,394 - 3,887 psi) Fuel Pressure Drop Across fuel filter ................................................................................................................................... ..................................... 35 kPa (5 psi) maximum Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions Air/Fuel Mixture: Technical Service Bulletins Fuel System/Engine Controls - Manual Revisions NUMBER: 26-02-99A GROUP: Miscellaneous DATE: February, 1999 REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN Models: 1998 Diagnostic Manual - Publication Number 81-699-97019 DESCRIPTION OF CHANGES Revision to the Diagnostic Trouble Codes Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1284 45 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1285 46 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1286 47 Revision to the Throttle Position Sensor connector pin outs Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1287 152 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1288 156 Revision to the Fuel System Rich test Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1289 316 Revisions to the Throttle Position sensor Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1290 620 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System Information > Technical Service Bulletins > Fuel System/Engine Controls - Manual Revisions > Page 1291 622 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Idle Speed - Effects of Incorrect Adjustment Idle Speed: Technical Service Bulletins Idle Speed - Effects of Incorrect Adjustment NO: 18-07-98 GROUP: Vehicle Performance DATE: Feb. 27, 1998 SUBJECT: Effects Of Incorrect Idle Speed MODELS: 1994 - 1998 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO THE 5.9L CUMMINS MECHANICALLY INJECTED 12 VALVE DIESEL. DISCUSSION: Incorrect idle adjustments (either too high or low) may cause many different customer concerns. Following is a list of items that explain the condition/symptoms associated with incorrect idle settings along with component checks and specifications to set it properly. RPM BELOW SPECIFICATION Hard Starting/Stalling during cold engine operation. Engine roughness at idle. Reduction in the amount of vacuum available during idle from vacuum pump. Delayed power steering assist When cold. Excess seat shake and/or mirror vibration. RPM ABOVE SPECIFICATION Excess creep at stoplights/signs. Vehicle does not reduce speed with foot off throttle. Typically low idle speed is caused by a misadjusted low idle speed screw on the injection pump but high idle speeds can be caused by many items. The list will help in diagnosing high idle concerns: The idle speed specifications for 1994 to 1998 models are 750 to 800 RPM. All idle speed measurements must be taken as follows: Automatic Transmission In drive with A/C switched on Manual Transmission In neutral with A/C switched on When making idle speed adjustments, always use a DRB III, or an optical tachometer such as Cummins 3377462, Snap On MT139 or equivalent to read engine idle RPM. NOTE: DO NOT USE THE TACHOMETER IN THE INSTRUMENT CLUSTER TO SET OR VERIFY IDLE SPEEDS. THIS TACHOMETER IS NOT Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Idle Speed - Effects of Incorrect Adjustment > Page 1296 ACCURATE FOR READING OR SETTING LOW RPM DURING IDLE CONDITIONS. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1297 Idle Speed: Specifications Idle Speed (A/T In Drive, A/C On) ....................................................................................................... ............................................................. 750-800 rpm Idle Speed (M/T In Neutral, A/C On) ................ ........................................................................................................................................................ 780 rpm Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1298 Idle Speed: Adjustments The high-speed idle screw is factory sealed and cannot be adjusted. Low-speed idle can be adjusted. 1. Use an optical tachometer such as Snap-on No. MT139 or MTE (Cummins tool division) No. 3377462 to read the engine RPM. 2. Bring the engine to normal operating temperature. Low Idle Speed Screw 3. Adjust the low idle speed at the low idle speed screw. The screw and locknut are located at the rear of the fuel injection pump. 4. Loosen the idle screw lock nut. Adjust idle screw to obtain specified RPM. LOW IDLE SPEED With automatic transmission: 750-800 RPM - with transmission in drive and air conditioning on. With manual transmission: * 780 RPM - with transmission in neutral and air conditioning on. * With engine at operating temperature. HIGH IDLE SPEED Do not attempt to adjust high idle speed. High idle speed adjustment screw is factory sealed. - Breaking seal will void injection pump warranty 5. Tighten the locknut after adjustment. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Testing and Inspection Air Cleaner Housing: Testing and Inspection TESTING AIR CLEANER ELEMENT Air Cleaner Housing CAUTION: Do not attempt to unnecessarily remove the top of the air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing is equipped with an air Filter Minder gauge. This air flow restriction gauge will determine when the air cleaner element is restricted and should be replaced. Filter Minder The Filter Minder consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc attached to the diaphragm moves along a graduated scale on the side of the Filter Minder. After the engine has been shut off, a ratcheting device located within the Filter Minder will hold the yellow disc at the highest restriction that the air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves the diaphragm and the yellow disc will indicate the size of the air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage the plastic housing of the Filter Minder. Cover and tape the Filter Minder if any engine degreasers or cleaners are to be used. To test, turn the engine off. If the yellow disc has reached the red colored zone on the graduated scale, the air cleaner element should be replaced. Resetting the Filter Minder: After the air cleaner (filter) element has been replaced, press the rubber button on the top of the Filter Minder. This will allow the yellow colored disc to reset. After the button has been pressed, the yellow disc should spring back to the UP position. If the Filter Minder gauge has reached the red colored zone, and after an examination of the air cleaner (filter) element, the element appears to be clean, the high reading may be due to a temporary condition such as snow build-up at the air intake. Temporary high restrictions may also occur if the air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow the element to dry out during normal engine operation. Reset the rubber button on the top of the Filter Minder and retest after the element has dried. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Testing and Inspection > Page 1302 Air Cleaner Housing: Service and Repair REMOVAL/INSTALLATION 1. Loosen the air inlet tube clamp at air cleaner housing inlet. Remove this tube at air cleaner housing cover. 2. The housing cover is equipped with four (4) spring clips and is hinged at the front with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and forward for cover removal. 3. Remove the air cleaner element from air cleaner housing. 4. Before installing a new air cleaner element, clean inside of air cleaner housing. 5. Position air cleaner cover to tabs on front of air cleaner housing. Latch the four spring clips to seal cover to housing. 6. Install the air inlet tube at air cleaner housing inlet. Note the hose alignment notches at both the inlet hose and air cleaner cover. 7. Position the tube clamp to the inlet tube and tighten to 3 Nm (25 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Requirements Fuel Filter: Technical Service Bulletins Fuel Filter - Requirements NO: 14-02-98 GROUP: Fuel DATE: Mar. 27, 1998 SUBJECT: Fuel Filter Requirements MODELS: 1998 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO DIESEL ENGINE APPLICATIONS. DISCUSSION: With the introduction of the Cummins 24 valve electronically injected engine, a new VP44 injection pump was also introduced. The VP44 injection pump requires finer fuel filtration due to tighter tolerances within the pump. Whenever a fuel filter is replaced, make sure the replacement filter is p/n 04883963AB. NOTE: DO NOT USE OLDER STYLE FILTERS ON THE 24 VALVE ENGINE. THE OLDER STYLE FILTER DOES NOT FILTER TO A FINE ENOUGH LEVEL FOR THE INJECTION PUMP USED ON THE 24 VALVE ENGINE. The new style filter (p/n 04883963AB) can be used on 1997/1998 12 valve engine applications. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 1307 Fuel Filter: Locations Fig 63 Fuel Filter/Water Separator Location The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains a fuel filter cartridge and Water-In-Fuel (WIF) sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 1308 Fuel Filter: Service and Repair Fig 63 Fuel Filter/Water Separator Location FUEL FILTER/WATER SEPARATOR Whenever the fuel filter is being replaced, the pre-filter in the fuel heater assembly should be removed and cleaned. Refer to Fuel Heater Removal/Installation for procedures. The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains a fuel filter cartridge and Water-In-Fuel (WIF) sensor. REMOVAL The canister drain valve serves two purposes. One is to partially drain the filter canister of excess water. The other is to completely drain the canister for filter replacement. DRAINING WATER FROM FILTER CANISTER: The filter should be drained whenever the water-in-fuel warning lamp remains illuminated. (Note that the lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). A drain hose is located at bottom of drain valve. Place a drain pan under drain hose. With engine not running, rotate valve handle forward to DRAIN position. Hold drain valve open until all water and contaminants have been removed and clean fuel exits the drain hose. If fuel filter or WIF sensor is being replaced, drain the canister completely. Dispose of mixture in drain pan according to applicable regulations. After draining operation, rotate valve handle rearward to CLOSE position. If fuel filter or WIF sensor is being replaced, proceed to next step. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 1309 Fig 64 Drain Valve At Fuel Filter/Water Separator 1. Remove drain hose at drain valve. 2. Disconnect Water-In-Fuel (WIF) sensor electrical connector pigtail harness from main engine wiring harness. The WIF sensor is located at side of filter canister. 3. Remove filter canister nut at top of header. 4. Lower canister assembly from header. 5. Remove and discard center O-ring. 6. Remove filter element (cartridge) from canister. 7. Remove WIF sensor and its seal from canister. 8. Inspect WIF sensor probes. Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up. INSTALLATION 1. Clean inside of canister. 2. Install a new O-ring seal to WIF sensor. 3. Install WIF sensor to canister. Tighten to 2-3 N.m (15-20 in. lbs.) torque. 4. If drain valve assembly is being replaced, tighten mounting screws to 3-5 N.m (3040 in. lbs.) torque. 5. Install new seal between canister and canister header. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 1310 Fig 65 Fuel Filter/Water Separator Components Fig 66 Water In Fuel Sensor NOTE: If filter canister is not filled with clean diesel fuel before installation, manual air bleeding of the fuel system may be necessary (temporary rough engine running may occur). If necessary, refer to the Air Bleed Procedure. 6. Fill filter canister with clean diesel fuel. 7. Apply a light film of clean diesel oil to seals. 8. Position canister assembly to canister header. - Note that the locating tabs on canister should align into header tab on canister header. - This step must be followed to prevent damage to canister or header and to prevent contact of drain valve into throttle linkage. 9. Install canister nut and tighten to 14 N.m (10 ft. lbs.) torque. 10. Connect electrical connector to WIF sensor. 11. Connect drain hose to bottom of drain valve. 12. Start engine and check for leaks. AIR BLEED PROCEDURE NOTE: A certain amount of air becomes trapped in the fuel system when fuel system components are serviced or replaced. Bleed the system after fuel system service according to the following procedures. WARNING: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system. MANUAL BLEEDING Some air enters the fuel system when the filters or injection pump supply line are changed. This small amount of air is vented automatically from the injection pump through the fuel drain manifold. This is if the filter was changed according to instructions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 1311 The system may have to be bled manually if: - The vehicle fuel tank has been allowed to run empty - The fuel filter is not filled before installation - The fuel injection pump is replaced - High-pressure fuel line connections are loosened or lines replaced - Initial engine start-up or start-up after an extended period of no engine operation. 1. Loosen the low-pressure bleed bolt. 2. Operate the rubber push-button primer on the fuel transfer pump. Do this until the fuel exiting the low-pressure bleed bolt is free of air. 3. Tighten low-pressure bleed screw to 8 N.m (6 ft. lbs.) torque. FUEL INJECTION PUMP BLEEDING WARNING: The engine may start when cranking to bleed air from the injection pump place the transmission in neutral or park and set parking brake before engaging the starter motor. CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. 1. Perform the previous procedure: Manual Bleeding. 2. Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold. - Observe the previous WARNING and CAUTION. HIGH-PRESSURE FUEL LINE BLEEDING WARNING: The fuel injection pump supplies high-pressure fuel of as high as 120,000 kPa (17,405 psi) to each individual injector through the high-pressure lines. Fuel under this amount of pressure can penetrate the skin and cause personal injury. Wear safety goggles and adequate protective clothing and avoid contact with fuel spray when bleeding high- pressure fuel lines. WARNING: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system. Bleed air from one injector at time. 1. Loosen the high-pressure fuel line fitting at the injector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Page 1312 2. Crank the engine until all air is bled from the line. - Do not operate the starter motor for longer than 30 seconds. - Wait two minutes between cranking intervals. 3. Start the engine and bleed one injector at a time until the engine runs smoothly. 4. Tighten fuel line(s) at injector(s) to 30 N.m (22 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications Firing Order The cylinders are numbered front to rear; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations Firing Order The cylinders are numbered front to rear; 1 to 6. The firing order is 1-5-3-6-2-4. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs. 3. Secure the throttle in the wide-open position. 4. Disable the fuel system. 5. Disconnect the ignition coil. 6. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 7. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications Intake ................................................................................................................................................... ............................................ 0.254 mm (0.010 inch) Exhaust ................................................................................................................................................ ............................................. 0.508 mm (0.020 inch) Note: Adjust valves when the engine is cold, below 60°C (140 °F). Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1326 Valve Clearance: Adjustments Locating TDC Using Timing Pin Use the timing pin to locate Top Dead Center (TDC) for cylinder No.1. The timing pin is located at the back of the gear housing and below the injection pump. Be sure to disengage the timing pin after locating top dead center. Adjust the valves when the engine is cold, below 60°C (140°F). Adjusting Valve Clearance STEP 1 Adjust the clearance for the valves shown above. The valve lash adjustment is 0.254 mm (0.010 inch) for the intake valve. The valve lash adjustment is 0.508 mm (0.020 inch) for the exhaust valve. Tighten the valve adjusting nuts to 24 N-m (18 ft. lbs.) torque. Be sure timing pin is disengaged before rotating the crankshaft. Mark the pulley and rotate the crankshaft 360°. Adjusting Valve Clearance STEP 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1327 Adjust the clearance for the valves shown above. The valve lash adjustment is 0.254 mm (0.010 inch) for the intake valve. The valve lash adjustment is 0.508 mm (0.020 inch) for the exhaust valve. Tighten the bolts to 24 Nm (18 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions Drive Belt: Service Precautions NOTE: The belt routing schematics are published from the latest information available at the time of publication. If anything differs between these schematics and the Belt Routing Label, use the schematics on Belt Routing Label. This label is located in the engine compartment. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Refer to Automatic Belt Tensioner. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions > Page 1331 Drive Belt: Description and Operation GENERAL INFORMATION All vehicles are available with either a 3.9L V-6, a 5.2L V-8, two different 5.9L V-8 engines, an 8.0L V-10 or a 5.9L in-line 6 cylinder diesel engine. The accessory drive components are operated by a single, crankshaft driven, serpentine drive belt on all engines. An automatic belt tensioner is also used to maintain correct belt tension at all times. This is used on all engines. DESCRIPTION Belt Tensioner-3.9L V-6 Or 5.2/5.9L V-8 LDC-Gas Engines Belt Tensioner-5.9L HDC-Gas And 8.0L V-10 Engines Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions > Page 1332 Belt Tensioner-5.9L Diesel-Typical (Non-A/C Shown) Drive belts on all engines are equipped with a spring loaded automatic belt tensioner. This belt tensioner will be used with all belt configurations, such as with or without power steering or air conditioning. CAUTION: Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner. Indexing Marks-3.9L V-6 Or 5.2/5.9L V-8 LDC-Gas Engines On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, the tensioner is equipped with an indexing arrow on back of tensioner and an indexing mark on tensioner housing. If a new belt is being installed, arrow must be within approximately 3 mm (1/8 inch) of indexing mark (point B-). Belt is considered new if it has been used 15 minutes or less. If this specification cannot be met, check for: The wrong belt being installed (incorrect length/ width) - Worn bearings on an engine accessory (A/C compressor, power steering pump, water pump, idler pulley or generator) - A pulley on an engine accessory being loose - Misalignment of an engine accessory - Belt incorrectly routed. On 3.9L V-6 or 5.2/5.9L V-8 LDC-gas engines, a used bell; should be replaced if tensioner indexing arrow has moved to point-A. Tensioner travel stops at point-A. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions > Page 1333 Drive Belt: Testing and Inspection VISUAL DIAGNOSIS Belt Wear Patterns When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. Part 1 Of 2 Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions > Page 1334 Part 2 Of 2 DIAGNOSIS CHART Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions > Page 1335 Drive Belt: Service and Repair REMOVAL Belt Tensioner-5.9L Diesel-Typical (non-A/C Shown) Drive belts on diesel engines are equipped with a spring loaded automatic belt tensioner.Image displays the tensioner for vehicles without air conditioning. This belt tensioner will be used on all belt configurations, such as with or without air conditioning. For more information, refer to Automatic Belt Tensioner. 1. A 3/8 inch square hole is provided in the automatic belt tensioner. Attach a 3/8 inch drive-long handle ratchet to this hole. 2. Rotate ratchet and tensioner assembly counterclockwise (as viewed from front) until tension has been relieved from belt. 3. Remove belt from water pump pulley first. 4. Remove belt from vehicle. INSTALLATION Belt Routing-5.9L Diesel Engine-With A/C Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service Precautions > Page 1336 Belt Routing-5.9L Diesel Engine-Without A/C CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to images for correct engine belt routing. The correct belt with correct length must be used. 1. Position drive belt over all pulleys except water pump pulley. 2. Attach a 3/8 inch ratchet to tensioner. 3. Rotate ratchet and belt tensioner counterclockwise. Place belt over water pump pulley. Let tensioner rotate back into place. Remove ratchet. Be sure belt is properly seated on all pulleys. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Testing and Inspection Air Cleaner Housing: Testing and Inspection TESTING AIR CLEANER ELEMENT Air Cleaner Housing CAUTION: Do not attempt to unnecessarily remove the top of the air cleaner housing for air cleaner element inspection on diesel engines. The air cleaner (filter) housing is equipped with an air Filter Minder gauge. This air flow restriction gauge will determine when the air cleaner element is restricted and should be replaced. Filter Minder The Filter Minder consists of a diaphragm and calibrated spring sealed inside of a plastic housing. A yellow colored disc attached to the diaphragm moves along a graduated scale on the side of the Filter Minder. After the engine has been shut off, a ratcheting device located within the Filter Minder will hold the yellow disc at the highest restriction that the air cleaner element has experienced. A drop in air pressure due to an air cleaner element restriction moves the diaphragm and the yellow disc will indicate the size of the air drop. CAUTION: Certain engine degreasers or cleaners may discolor or damage the plastic housing of the Filter Minder. Cover and tape the Filter Minder if any engine degreasers or cleaners are to be used. To test, turn the engine off. If the yellow disc has reached the red colored zone on the graduated scale, the air cleaner element should be replaced. Resetting the Filter Minder: After the air cleaner (filter) element has been replaced, press the rubber button on the top of the Filter Minder. This will allow the yellow colored disc to reset. After the button has been pressed, the yellow disc should spring back to the UP position. If the Filter Minder gauge has reached the red colored zone, and after an examination of the air cleaner (filter) element, the element appears to be clean, the high reading may be due to a temporary condition such as snow build-up at the air intake. Temporary high restrictions may also occur if the air cleaner (filter) element has gotten wet such as during a heavy rain or snow. If this occurs, allow the element to dry out during normal engine operation. Reset the rubber button on the top of the Filter Minder and retest after the element has dried. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Testing and Inspection > Page 1341 Air Cleaner Housing: Service and Repair REMOVAL/INSTALLATION 1. Loosen the air inlet tube clamp at air cleaner housing inlet. Remove this tube at air cleaner housing cover. 2. The housing cover is equipped with four (4) spring clips and is hinged at the front with plastic tabs. Unlatch the clips from the top of air cleaner housing and tilt the housing cover up and forward for cover removal. 3. Remove the air cleaner element from air cleaner housing. 4. Before installing a new air cleaner element, clean inside of air cleaner housing. 5. Position air cleaner cover to tabs on front of air cleaner housing. Latch the four spring clips to seal cover to housing. 6. Install the air inlet tube at air cleaner housing inlet. Note the hose alignment notches at both the inlet hose and air cleaner cover. 7. Position the tube clamp to the inlet tube and tighten to 3 Nm (25 in. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications Fluid Filter - A/T: Specifications Mounting Screw ................................................................................................................................... ................................................... 4 Nm (35 inch lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Requirements Fuel Filter: Technical Service Bulletins Fuel Filter - Requirements NO: 14-02-98 GROUP: Fuel DATE: Mar. 27, 1998 SUBJECT: Fuel Filter Requirements MODELS: 1998 (BR/BE) Ram Truck NOTE: THIS INFORMATION APPLIES TO DIESEL ENGINE APPLICATIONS. DISCUSSION: With the introduction of the Cummins 24 valve electronically injected engine, a new VP44 injection pump was also introduced. The VP44 injection pump requires finer fuel filtration due to tighter tolerances within the pump. Whenever a fuel filter is replaced, make sure the replacement filter is p/n 04883963AB. NOTE: DO NOT USE OLDER STYLE FILTERS ON THE 24 VALVE ENGINE. THE OLDER STYLE FILTER DOES NOT FILTER TO A FINE ENOUGH LEVEL FOR THE INJECTION PUMP USED ON THE 24 VALVE ENGINE. The new style filter (p/n 04883963AB) can be used on 1997/1998 12 valve engine applications. POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 1349 Fuel Filter: Locations Fig 63 Fuel Filter/Water Separator Location The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains a fuel filter cartridge and Water-In-Fuel (WIF) sensor. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 1350 Fuel Filter: Service and Repair Fig 63 Fuel Filter/Water Separator Location FUEL FILTER/WATER SEPARATOR Whenever the fuel filter is being replaced, the pre-filter in the fuel heater assembly should be removed and cleaned. Refer to Fuel Heater Removal/Installation for procedures. The fuel filter/water separator assembly is located on left/rear side of engine above starter motor. The assembly contains a fuel filter cartridge and Water-In-Fuel (WIF) sensor. REMOVAL The canister drain valve serves two purposes. One is to partially drain the filter canister of excess water. The other is to completely drain the canister for filter replacement. DRAINING WATER FROM FILTER CANISTER: The filter should be drained whenever the water-in-fuel warning lamp remains illuminated. (Note that the lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check). A drain hose is located at bottom of drain valve. Place a drain pan under drain hose. With engine not running, rotate valve handle forward to DRAIN position. Hold drain valve open until all water and contaminants have been removed and clean fuel exits the drain hose. If fuel filter or WIF sensor is being replaced, drain the canister completely. Dispose of mixture in drain pan according to applicable regulations. After draining operation, rotate valve handle rearward to CLOSE position. If fuel filter or WIF sensor is being replaced, proceed to next step. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 1351 Fig 64 Drain Valve At Fuel Filter/Water Separator 1. Remove drain hose at drain valve. 2. Disconnect Water-In-Fuel (WIF) sensor electrical connector pigtail harness from main engine wiring harness. The WIF sensor is located at side of filter canister. 3. Remove filter canister nut at top of header. 4. Lower canister assembly from header. 5. Remove and discard center O-ring. 6. Remove filter element (cartridge) from canister. 7. Remove WIF sensor and its seal from canister. 8. Inspect WIF sensor probes. Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up. INSTALLATION 1. Clean inside of canister. 2. Install a new O-ring seal to WIF sensor. 3. Install WIF sensor to canister. Tighten to 2-3 N.m (15-20 in. lbs.) torque. 4. If drain valve assembly is being replaced, tighten mounting screws to 3-5 N.m (3040 in. lbs.) torque. 5. Install new seal between canister and canister header. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 1352 Fig 65 Fuel Filter/Water Separator Components Fig 66 Water In Fuel Sensor NOTE: If filter canister is not filled with clean diesel fuel before installation, manual air bleeding of the fuel system may be necessary (temporary rough engine running may occur). If necessary, refer to the Air Bleed Procedure. 6. Fill filter canister with clean diesel fuel. 7. Apply a light film of clean diesel oil to seals. 8. Position canister assembly to canister header. - Note that the locating tabs on canister should align into header tab on canister header. - This step must be followed to prevent damage to canister or header and to prevent contact of drain valve into throttle linkage. 9. Install canister nut and tighten to 14 N.m (10 ft. lbs.) torque. 10. Connect electrical connector to WIF sensor. 11. Connect drain hose to bottom of drain valve. 12. Start engine and check for leaks. AIR BLEED PROCEDURE NOTE: A certain amount of air becomes trapped in the fuel system when fuel system components are serviced or replaced. Bleed the system after fuel system service according to the following procedures. WARNING: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system. MANUAL BLEEDING Some air enters the fuel system when the filters or injection pump supply line are changed. This small amount of air is vented automatically from the injection pump through the fuel drain manifold. This is if the filter was changed according to instructions. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 1353 The system may have to be bled manually if: - The vehicle fuel tank has been allowed to run empty - The fuel filter is not filled before installation - The fuel injection pump is replaced - High-pressure fuel line connections are loosened or lines replaced - Initial engine start-up or start-up after an extended period of no engine operation. 1. Loosen the low-pressure bleed bolt. 2. Operate the rubber push-button primer on the fuel transfer pump. Do this until the fuel exiting the low-pressure bleed bolt is free of air. 3. Tighten low-pressure bleed screw to 8 N.m (6 ft. lbs.) torque. FUEL INJECTION PUMP BLEEDING WARNING: The engine may start when cranking to bleed air from the injection pump place the transmission in neutral or park and set parking brake before engaging the starter motor. CAUTION: Do not engage the starter motor for more than 30 seconds at a time. Allow two minutes between cranking intervals. 1. Perform the previous procedure: Manual Bleeding. 2. Crank the engine for 30 seconds at a time to allow air trapped in the injection pump to vent out the drain manifold. - Observe the previous WARNING and CAUTION. HIGH-PRESSURE FUEL LINE BLEEDING WARNING: The fuel injection pump supplies high-pressure fuel of as high as 120,000 kPa (17,405 psi) to each individual injector through the high-pressure lines. Fuel under this amount of pressure can penetrate the skin and cause personal injury. Wear safety goggles and adequate protective clothing and avoid contact with fuel spray when bleeding high- pressure fuel lines. WARNING: Do not bleed air from the fuel system of a hot engine. Do not allow fuel to spray onto the exhaust manifold when bleeding air from the fuel system. Bleed air from one injector at time. 1. Loosen the high-pressure fuel line fitting at the injector. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Page 1354 2. Crank the engine until all air is bled from the line. - Do not operate the starter motor for longer than 30 seconds. - Wait two minutes between cranking intervals. 3. Start the engine and bleed one injector at a time until the engine runs smoothly. 4. Tighten fuel line(s) at injector(s) to 30 N.m (22 ft. lbs.) torque. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Some Oil Filters May Cause Damage Oil Filter: Technical Service Bulletins Engine - Some Oil Filters May Cause Damage NUMBER: 09-004-01 GROUP: Engine DATE: May 18,2001 SUBJECT: Engine Lubrication MODELS: 1989 - 1993 (AD) Ram Truck 1994 - 2001 (BR/BE) Ram Truck NOTE: THIS BULLETIN INVOLVES 1989-2001 MY 2500 AND 3500 RAM TRUCKS EQUIPPED WITH THE 5.9L CUMMINS DIESEL ENGINE. DISCUSSION: Customer may complain of high oil consumption, grey oil smoke coming out of the exhaust or breather tube, or mechanical knocking. Neoprene compounds used internally in the manufacture of oil filters not recommended by DaimlerChrysler may separate from the filter, lodge in the piston cooling nozzle, and can fail the engine. NOTE: THIS IS NOT AN ENGINE DEFECT. (See the table for a list of oil filters recommended by DaimlerChrysler for use with the 5.9L Cummins diesel engine.) NOTE: SECTION 2.7 OF THE TRUCK WARRANTY MANUAL STATES "DAIMLERCHRYSLER MOTORS CORPORATION IS NOT RESPONSIBLE FOR FAILURES RESULTING FROM IMPROPER REPAIR OR THE USE OF PARTS WHICH ARE NOT GENUINE DAIMLERCHRYSLER MOTORS CORPORATION / MOPAR OR DIAMLERCHRYSLER MOTORS CORPORATION / MOPAR APPROVED PARTS." DAMAGES CAUSED BY THE USE OF OIL FILTERS NOT APPROVED BY DAIMLERCHRYSLER MAY NOT BE COVERED BY THE NEW VEHICLE WARRANTY. DAIMLERCHRYSLER RECOMMENDS THE FOLLOWING OIL FILTERS. DO NOT USE ANY OIL FILTER CONTAINING NEOPRENE. PLEASE SHARE THIS WITH YOUR CUSTOMERS. RECOMMENDED OIL FILTERS FOR USE WITH CUMMINS 5.9L DIESEL ENGINE: POLICY: Information Only Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications Oil Filter: Mechanical Specifications 3/4 Turn After Gasket Contact Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Mechanical Specifications > Page 1361 Oil Filter: Pressure, Vacuum and Temperature Specifications Differential Pressure to Open Filter Bypass: 172.3 kPa (25 psi) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1362 Oil Filter: Application and ID All Dodge Ram engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar, or equivalent, oil filter be used. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1363 Oil Filter: Description and Operation When replacing the oil filter, use replacement filter specified in your Operator's Manual. CAUTION: The internal filtering medium of some filters has been known to disintegrate. Debris from failed filters may plug the piston oil cooling nozzles, resulting in scuffed pistons and eventual engine failure. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal and Installation Oil Filter: Service and Repair Removal and Installation REMOVAL 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench, loosen filter. Oil Filter Removal-Typical 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. Oil Filter Sealing Surface-Typical 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil or chassis grease. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten. 3. Add oil, verify crankcase oil level, and start engine. Inspect for oil leaks. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Removal and Installation > Page 1366 Oil Filter: Service and Repair Bypass Valve REMOVAL Removing Filter Bypass Valve 1. Remove the oil cooler cover. 2. Remove the valve from the cooler cover. INSTALLATION Installing New Filter Bypass Valve 1. Drive the new valve in until it bottoms against the step in the bypass valve bore. 2. Install the oil cooler cover. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions Hose/Line HVAC: Service Precautions Refrigerant Hoses/Lines/Tubes Precautions Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system. High pressures are produced in the system when it is operating. Extreme care must be exercised to make sure that all refrigerant system connections are pressure tight. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. Sharp bends will reduce the flow of refrigerant. The flexible hose lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. It is a good practice to inspect all flexible refrigerant system hose lines at least once a year to make sure they are in good condition and properly routed. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service Precautions > Page 1371 Hose/Line HVAC: Description and Operation Refrigerant Line The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components. A barrier hose design with a nylon tube inner hose liner is used for the R-134a air conditioning system on this vehicle. This nylon liner helps to further contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant hoses are made from lightweight aluminum, and use braze-less fittings. Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the suction line refrigerant line coupler at the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the block fitting to the stud on the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. On models with a gasoline engine, remove the nut that secures the refrigerant line support bracket to the stud on the compressor mounting bracket. Suction And Discharge Line Remove/Install - Diesel Engine 7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Connect the suction line refrigerant line coupler to the accumulator. 2. Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 N.m (180 in. lbs.). 3. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.). 4. On models with a gasoline engine, install the nut that secures the refrigerant line support bracket to the stud on the compressor mounting bracket. Tighten the mounting nut to 22 N.m (200 in. lbs.). 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1374 Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Disconnect the liquid line refrigerant line couplers at the condenser outlet and the evaporator inlet. Install plugs in, or tape over all of the opened refrigerant line fittings. Liquid Line Remove/Install 4. Disengage any clips that secure the liquid line to the inner fender shield and the dash panel. 5. Remove the liquid line from the vehicle. INSTALLATION 1. Install the liquid line into any clips on the inner fender shield and the dash panel. 2. Remove the tape or plugs from the refrigerant line fittings on the liquid line, the condenser outlet, and the evaporator inlet. Connect the liquid line to the condenser and the evaporator. 3. Connect the battery negative cable. 4. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 5. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Hose/Line Replacement > Page 1375 Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold. High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Recover the refrigerant from the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Unplug the wire harness connector from the high pressure cut-off switch. 4. Disconnect the suction line refrigerant line coupler at the accumulator. Install plugs in, or tape over all of the opened refrigerant line fittings. 5. Remove the nut that secures the block fitting to the stud on the condenser inlet and disconnect the discharge line from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. On models with a gasoline engine, remove the nut that secures the refrigerant line support bracket to the stud on the compressor mounting bracket. Suction And Discharge Line Remove/Install - Diesel Engine 7. Remove the screw that secures the refrigerant line manifold to the compressor. Install plugs in, or tape over all of the opened refrigerant line fittings. 8. Remove the suction and discharge line assembly from the vehicle. INSTALLATION 1. Remove the tape or plugs from all of the refrigerant line fittings. Connect the suction line refrigerant line coupler to the accumulator. 2. Install a new gasket and the discharge line block fitting over the stud on the condenser inlet. Tighten the mounting nut to 20 N.m (180 in. lbs.). 3. Install the refrigerant line manifold to the compressor. Tighten the mounting screw to 22 N.m (200 in. lbs.). 4. On models with a gasoline engine, install the nut that secures the refrigerant line support bracket to the stud on the compressor mounting bracket. Tighten the mounting nut to 22 N.m (200 in. lbs.). 5. Plug in the wire harness connector to the high pressure cut-off switch. 6. Connect the battery negative cable. 7. Evacuate the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate 8. Charge the refrigerant system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Charge, See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-003-02 > Apr > 02 > Power Steering - Hissing Sound Power Steering Line/Hose: Customer Interest Power Steering - Hissing Sound NUMBER: 19-003-02 GROUP: Steering DATE: April 15, 2002 SUBJECT: Hissing Sound Coming From The Power Steering System On Vehicles Equipped With Hydroboost Brakes OVERVIEW: This bulletin involves Replacing the power steering hoses connecting the Hydroboost to the power steering pump and gear. MODELS: 1997 - 2002 BR/BE Ram Truck SYMPTOM/CONDITION: A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. DIAGNOSIS: If the vehicle exhibits the condition perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Drain the power steering fluid from the system. 2. Remove the pressure hose from the power steering pump to the Hydroboost. 3. Install the new hose, p/n 05086529AA. 4. Remove the pressure hose from the Hydroboost to the steering gear. 5. Install the new hose, p/n 05086532AA. 6. Check the routing of the hoses to ensure no interference problems exist. Use tie straps to secure the hoses if necessary. 7. Fill the system with power steering fluid and operate the steering system to purge any air from the system POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-003-02 > Apr > 02 > Power Steering Hissing Sound Power Steering Line/Hose: All Technical Service Bulletins Power Steering - Hissing Sound NUMBER: 19-003-02 GROUP: Steering DATE: April 15, 2002 SUBJECT: Hissing Sound Coming From The Power Steering System On Vehicles Equipped With Hydroboost Brakes OVERVIEW: This bulletin involves Replacing the power steering hoses connecting the Hydroboost to the power steering pump and gear. MODELS: 1997 - 2002 BR/BE Ram Truck SYMPTOM/CONDITION: A hissing sound may be present in the power steering system during steering maneuvers or straight ahead driving. DIAGNOSIS: If the vehicle exhibits the condition perform the Repair Procedure. PARTS REQUIRED REPAIR PROCEDURE: 1. Drain the power steering fluid from the system. 2. Remove the pressure hose from the power steering pump to the Hydroboost. 3. Install the new hose, p/n 05086529AA. 4. Remove the pressure hose from the Hydroboost to the steering gear. 5. Install the new hose, p/n 05086532AA. 6. Check the routing of the hoses to ensure no interference problems exist. Use tie straps to secure the hoses if necessary. 7. Fill the system with power steering fluid and operate the steering system to purge any air from the system POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Page 1389 Power Steering Line/Hose: Specifications Pressure Line ...................................................................................................................................... ...................................................... 31 Nm (23 ft. lbs.) Return Line ..................................................... .......................................................................................................................................... 31 Nm (23 ft. lbs.) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation Radiator Hose: Description and Operation GENERAL INFORMATION Rubber hoses route coolant to and from the radiator, intake manifold and heater core. Radiator lower hoses are spring-reinforced to prevent collapse from water pump suction at moderate and high engine speeds. Inspect the hoses at regular intervals. Replace hoses that are cracked, feel brittle when squeezed or swell excessively when system is pressurized. The use of molded replacement hoses is recommended. When performing a hose inspection, inspect radiator lower hose for proper position and condition of spring. Hose Clamp Tool-Typical WARNING: Constant tension hose clamps are used on most cooling system hoses. When removing or installing, use only tools designed for servicing this type of clamp, such as special clamp tool (NUMBER 6094). Snap-on clamp tool (NUMBER HPC-20) may be used for larger clamps. Always wear safety glasses when servicing constant tension clamps. Clamp Number/Letter Location CAUTION: A number or letter is stamped into the tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp with a matching number or letter. Ordinary worm gear type hose clamps (when equipped) can be removed with a straight screwdriver or a hex socket. To prevent damage to hoses or clamps, the hose clamps should be tightened to 4 Nm (34 inch lbs.) torque. Do not over tighten hose clamps. For all vehicles: In areas where specific routing clamps are not provided, be sure that hoses are positioned with sufficient clearance. Check clearance from exhaust manifolds and pipe, fan blades, drive belts and sway bars. Improperly positioned hoses can be damaged, resulting in coolant loss and engine overheating. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1397 Brake Fluid: Testing and Inspection CAUTION: The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the rubber parts or components containing rubber coming into contact with the brake fluid. This includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS hydraulic control unit (HCU), and all hydraulic fluid hoses. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1398 Brake Fluid: Service and Repair FLUID LEVEL Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. Brake Fluid Level Inspection The fluid fill level is indicated on the side of the master cylinder reservoir. The correct fluid level is to the FULL indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications CLUTCH FLUID TYPE Use brake fluid meeting DOT 3 specifications and SAE J1703 standards. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ......................................................... 24.5 L (26 qts) Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1406 Coolant: Fluid Type Specifications The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68% antifreeze concentration, which prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. 100 Percent Ethylene-Glycol Should Not Be Used Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F). Propylene-Glycol Formulations Should Not Be Used Propylene-glycol formulations do not meet the required specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at 96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics than ethylene-glycol. This can increase cylinder head temperatures under certain conditions. Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the freeze point will not be accurate. Both the refractive index and specific gravity differ between the ethylene-glycol and propylene-glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information Coolant: Description and Operation General Information The cooling system is designed around the coolant. Coolant flows through the engine water jacket absorbing heat produced during engine operation. The coolant carries the heat to radiator and heater core. Here it is transferred to the ambient air passing through the radiator and heater core fins. The coolant also removes heat from the automatic transmission fluid in vehicles equipped with an automatic transmission. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1409 Coolant: Description and Operation Coolant Performance PREFERRED MIXTURE The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide protection against freezing to -37 deg. C (-35 deg. F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower than 44 percent, engine parts may be eroded by cavitation, and cooling system components may be severely damaged by corrosion. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7 deg. C (-90 deg. F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the specific heat of antifreeze is lower than that of water. UNACCEPTABLE MIXTURES 100 Percent Ethylene-Glycol Use of 100 percent ethylene-glycol will cause formation of additive deposits in the system, as the corrosion inhibitive additives in ethylene-glycol require the presence of water to dissolve. The deposits act as insulation, causing temperatures to rise to as high as 149 deg. C (300) deg. F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethylene-glycol freezes at 22 deg. C (-8 deg. F ). Propylene-glycol Formulations Propylene-glycol formulations do not meet Chrysler coolant specifications. It's overall effective temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg. C (-26 deg. F). 5 deg. C higher than ethylene-glycol's freeze point. The boiling point (protection against summer boil-over) of propylene-glycol is 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi), compared to 128 deg. C (263 deg. F) for ethylene-glycol. Use of propylene-glycol can result in boil-over or freeze-up in Chrysler vehicles, which are designed for ethylene-glycol. Propylene glycol also has poorer heat transfer characteristics than ethylene glycol. This can increase cylinder head temperatures under certain conditions. Propylene-glycol/Ethylene-glycol Mixtures Propylene-glycol/ethylene-glycol Mixtures can cause the destabilization of various corrosion inhibitors, causing damage to the various cooling system components. Also, once ethylene-glycol and propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining freeze point will not be accurate. Both the refractive index and specific gravity differ between ethylene glycol and propylene glycol. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > General Information > Page 1410 Coolant: Description and Operation Selection and Additives PURPOSE The presence of aluminum components in the cooling system requires strict corrosion protection. Maintain coolant at specified level with a mixture of ethylene glycol based antifreeze and water. Only use an antifreeze containing ALUGARD 340-2 (TM) such as Mopar Antifreeze. If coolant becomes contaminated or looses color, drain and flush cooling system and fill with correctly mixed solution. CAUTION: Do not use coolant additives that are claimed to improve engine cooling. Dodge Ram 2500 4wd Workshop Manual (Truck L6-359 5.9L DSL Turbo VIN D FI (1998)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1411 Coolant: Service and Repair Refer to Cooling System, Service and Repair for applicable service procedures.